3D Printed Support Material Verification via Photoluminescence
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Solution Overview
Problem
Existing three-dimensional printing systems face challenges in verifying the integrity of the post-process removal of support material from build material, which is crucial for ensuring the quality and accuracy of the manufactured articles.
Innovation Solution
A method involving the use of a support material ink with a phase change component and a phosphor component, where the support material is printed to provide support during the manufacturing process and is later removed by illuminating the article with electromagnetic radiation to inspect for photoluminescence, ensuring its complete removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If support material is used during 3D printing to support unsupported portions of build material, then manufacturing precision is improved, but verification of complete support material removal becomes difficult
Solution Approach 1:
The support material contains a phosphor component that exhibits photoluminescence when illuminated with electromagnetic radiation. This causes the support material to emit visible light, creating a visual contrast between remaining support material and the final article. This color/optical property change enables easy detection and verification of complete support material removal through simple illumination and visual inspection or imaging systems.
2Difficulty of detecting and measuring
If phosphor component is added to support material ink, then ease of detecting support material removal is improved, but device complexity increases
Solution Approach 1:
The phosphor component changes the optical parameters of the support material by introducing photoluminescence properties. When illuminated with electromagnetic radiation in a specific wavelength range, the phosphor emits light at a different wavelength, creating a detectable optical signal. This parameter change enables simple detection methods while maintaining relatively simple ink composition, as the phosphor is incorporated directly into the support material ink formulation.
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
This method allows for effective verification of the removal of support material, ensuring the integrity and quality of the three-dimensional article by utilizing the phosphor component's response to illumination, which is visible and quantifiable, thereby confirming the successful removal of the support material.
Implementation Method 1
illuminating the three-dimensional article with electromagnetic radiation, inspecting the three dimensional article for photoluminescence that is responsive to the illumination
Data Source
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AI summary
A method of manufacturing a three dimensional article includes forming the three- dimensional article with three-dimensional printing, processing the three-dimensional article to remove support material ink, illuminating the three-dimensional article with electromagnetic radiation, inspecting the three dimensional article for photoluminescence that is responsive to the illumination, and verifying whether the support material has been sufficiently removed based upon the inspection. The support material ink includes a phosphor component that phosphorescently emits light in response to the illumination.