3D Printing Device with Spray and Electron Beam Units
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Solution Overview
Problem
Current 3D printing methods are limited in producing complex components with diverse material requirements, as they typically use a single material and lack the capability to integrate different materials effectively in a single printing operation.
Innovation Solution
A 3D printing device combining a spray printing unit for applying materials in droplet form with an electron beam or laser unit for local melting, allowing for the integration of multiple materials and enabling the production of complex components by spraying and melting different materials layer by layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single material is used in 3D printing, then the process is simple and equipment requirements are low, but the capability to produce complex components with diverse material requirements is limited
Solution Approach 1:
The patent combines multiple material deposition technologies (inkjet printing, spray printing, extrusion) and multiple energy source technologies (laser, electron beam) into a single 3D printing system. This merging enables the system to handle diverse materials with different requirements while maintaining operational versatility, directly resolving the contradiction between adaptability and device complexity
Solution Approach 2:
The 3D printing device is designed with multi-functional capabilities to deposit different materials (metals, plastics, ceramics) using various deposition methods and to process them with different energy sources (laser for plastics, electron beam for metals). This universal design allows a single device to perform multiple functions that would traditionally require separate equipment, thereby improving adaptability without proportionally increasing device complexity
2Adaptability or versatility
If materials are sprayed on layer by layer like inkjet printing, then different materials can be applied, but the materials need to be cured under UV light which limits the types of materials that can be used
Solution Approach 1:
The patent changes the fundamental parameter of energy interaction by introducing electron beam technology alongside laser technology. While laser operates optically (requiring UV curing for plastics), electron beam operates through direct kinetic energy conversion to heat, enabling processing of metals and other materials that cannot be cured by UV light. This parameter change expands material selection versatility
Solution Approach 2:
The patent introduces an intermediary energy conversion mechanism where electron beam kinetic energy serves as a mediator to transfer energy to metal powders and other materials that are not responsive to UV curing. This intermediary approach enables the processing of diverse materials including metals, ceramics, and plastics without being constrained by UV curing requirements
3Manufacturing precision
If selective laser melting is used for metals, then metals can be melted locally, but the process requires high energy input and long processing time
Solution Approach 1:
The patent employs periodic pulsed electron beam action instead of continuous laser irradiation. The electron beam is activated in periodic pulses that precisely melt material only when needed, allowing rapid heating and cooling cycles. This periodic action reduces overall processing time while maintaining local melting precision, directly addressing the productivity concern
4Adaptability or versatility
If multiple materials are integrated in a single printing operation, then highly complex components with different material requirements can be produced, but the device complexity and process complexity increase
Solution Approach 1:
The patent segments the material deposition and energy processing functions into distinct modular units (inkjet printing unit, spray printing unit, extrusion unit, laser unit, electron beam unit). Each unit is optimized for specific material types and processing requirements. This segmentation allows complex multi-material components to be produced by coordinating simple, specialized modules rather than requiring a single complex integrated system, thereby managing device complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of highly complex three-dimensional components with varied material properties by integrating different materials, such as metals and plastics, within a single printing operation, enhancing the structural integrity and complexity of printed parts.
Implementation Method 1
a spray printing unit (3) for spraying on different materials (M1, M2)
Implementation Method 2
an electron beam and/or laser unit (2) for connecting sprayed-on material (M1, M2) in an integrally joined manner by way of melting by means of an electron beam and/or by means of a laser beam
Implementation Method 3
an electron beam and/or laser unit (2) for connecting sprayed-on material (M1, M2) in an integrally joined manner by way of melting by means of an electron beam and/or by means of a laser beam
Data Source
AI summary
A 3D printing device for producing a three-dimensional component form at least two different materials. The 3D printing device has both a spray-printing unit and an electron-beam and/or laser unit. To produce the three-dimensional component, the spray-printing unit is designed and set up to spray the at least two different materials, and the electron-beam and/or laser unit is designed and set up to join sprayed-on material integrally by fusing by means of an electron beam and/or by means of a laser beam of the electron-beam and/or laser unit.