Syringe Micro-Dispensing for 3D Objects with Curing
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Solution Overview
Problem
Current methods for 3D object manufacturing, such as screen printing and additive manufacturing, are limited by the need for flat surfaces, restricted material choices, and inability to handle high viscous materials with particles, and lack efficiency in layering and material removal.
Innovation Solution
A syringe-based micro-dispensing method that allows for the deposition and real-time curing of layers using various materials, including those with nano to micron-sized particles, and enables multiple nozzles to operate independently for parallel or series use, along with multiple curing sources and feedback systems for enhanced speed and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If screen printing is used for high speed patterning, then printing speed is improved, but the ability to produce 3D builds and high aspect ratio features is lost
Solution Approach 1:
The printing process is segmented into discrete layer deposition steps, where each layer is cured independently before the next is added. This allows incremental 3D construction while maintaining the speed advantages of rapid-cure technology at each stage.
Solution Approach 2:
The invention transitions from 2D screen printing to 3D construction by adding the vertical dimension through sequential layer deposition. Each layer is built upon the previous cured layer, enabling high aspect ratio features and true 3D geometries while preserving rapid printing capabilities.
2Adaptability or versatility
If ink jetting is used for multiple material additive building, then material versatility is improved, but the material choice is limited to low viscous materials with low to no particle loading
Solution Approach 1:
The invention replaces the inkjetting mechanism with a syringe-based dispensing system that uses mechanical control of material flow. This substitution enables handling of high viscosity materials and those with high particle loading, as the syringe system can directly dispense materials without requiring them to be jetted through fine nozzles.
Solution Approach 2:
The invention changes the material delivery parameters by using syringe dispensing instead of inkjetting, allowing materials with higher viscosity and particle content to be deposited. The system can control dispensing rate, pressure, and volume to accommodate a wide range of material properties including pastes, slurries, and composite materials.
3Adaptability or versatility
If Fused Deposition Modeling is used for 3D building, then material flexibility is improved, but the requirement for heat to melt material before extrusion is a limitation
Solution Approach 1:
The invention replaces the thermal melting and extrusion mechanism with a syringe-based direct dispensing system. Materials are deposited in their original state without requiring heating or melting, eliminating thermal constraints while maintaining the ability to use diverse materials including temperature-sensitive polymers, ceramics, and composite formulations.
Solution Approach 2:
The invention changes the material processing parameters by eliminating the heating step entirely. Materials are dispensed at ambient or controlled temperatures, expanding the range of usable materials to include those that would degrade, deform, or become unsafe at melting temperatures. The curing process occurs after deposition through UV, thermal, or chemical means rather than during extrusion.
4Use of energy by moving object
If standard stereolithography is used for additive manufacturing, then UV curing capability is improved, but the need for multiple vats for multiple materials is cumbersome
Solution Approach 1:
The syringe-based dispensing system serves multiple functions: it can deliver different materials through different syringes, control deposition patterns, and work with various curing methods (UV, thermal, chemical). This single platform replaces the need for multiple specialized vats, as each syringe can be loaded with a different material and the system can switch between them programmatically.
Solution Approach 2:
The syringe-based dispensing system acts as an intermediary between material storage and the curing process. Instead of having materials directly in vats exposed to UV, the system dispenses materials layer by layer and then applies curing. This intermediary approach enables precise material control, multi-material capability, and compatibility with various curing methods without requiring direct UV exposure of material reservoirs.
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 rapid and precise construction of 3D objects with complex shapes and multiple material layers, allowing for the integration of functional materials and circuits, and efficient material removal, thereby overcoming the limitations of existing technologies.
Implementation Method 1
A syringe-based micro-dispensing method that allows for the deposition and real-time curing of layers
Implementation Method 2
focusing a laser on the surface of the vat and polymerizing the polymer material via Ultra Violet (UV) curing process
Implementation Method 3
allowing for post processing the three dimensional structure at a sufficiently high temperature to burn off the material and leave the particles
Data Source
AI summary
A method of building a three dimensional (3D) structure includes micro-dispensing a layer comprising a material using a syringe-based micro-dispensing tool, curing the layer, and repeating the steps of micro-dispensing and curing a plurality of times in order to build the three-dimensional structure. The material may be loaded with nano to micron sized particles, tubes, or strings.