System and method for rapidly printing ice into a three-dimensional structure
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Solution Overview
Problem
Existing 3D printing technologies are limited by the use of cryogenic materials, which are expensive and dangerous, and struggle to produce large objects with high resolution and fine details, especially when using materials like polymer foams that expand during curing, and require multiple machines for different materials.
Innovation Solution
A 3D printing system that uses precooled water dispensed through precise bands onto an actively cooled transfer surface, which freezes and adheres to form high-resolution ice layers, allowing for precise pattern deposition and movement to create complex objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If water is sprayed onto a cooled surface for 3D printing, then the printing head is kept separated from the cooled surface, but the resolution is low and fine details are lost
Solution Approach 1:
A transfer surface acts as an intermediary between the dispensing head and the object being printed. Water bands are deposited onto the transfer surface, partially frozen there, then transferred to the object. This mediator enables both head separation and high resolution.
Solution Approach 2:
The deposition process is segmented into distinct stages: water bands are deposited onto the transfer surface, partially frozen, then transferred to the object. This segmentation allows optimization of each stage for both separation and resolution.
2Ease of manufacture
If cryogenic fluids are used to freeze water during printing, then water can be frozen into ice, but the process becomes expensive, complicated, and dangerous
Solution Approach 1:
The transfer surface is actively cooled and discarded (or reset) after each use, replacing the need for expensive cryogenic fluids. The cooling function is temporary and localized to the transfer surface.
Solution Approach 2:
The complex cryogenic fluid system is replaced with a simpler actively cooled transfer surface that uses controlled cooling to freeze water bands in place, eliminating dangerous cryogenic materials.
3Volume of moving object
If traditional 3D printing is used for large objects, then printing can be performed, but the process takes much longer than printing small objects
Solution Approach 1:
Water bands are partially frozen on the transfer surface before being transferred to the object. This preliminary freezing action enables faster deposition rates while maintaining structural integrity of large objects.
Solution Approach 2:
The actively cooled transfer surface enables continuous water band deposition and freezing without interruption, maintaining high productivity even as object volume increases.
4Manufacturing precision
If high resolution printing is performed, then fine details are achieved, but the deposit rate decreases and printing takes longer
Solution Approach 1:
The physical state of water is changed to bands that can be precisely controlled in width and placement. This parameter change enables high resolution deposition at faster rates compared to traditional methods.
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 production of large, high-resolution ice structures with fine details without cryogenic materials, using a single machine and maintaining precise tolerances, suitable for architectural and construction elements.
Implementation Method 1
The transfer surface is actively cooled. When the water bands contact the transfer surface, the water partially freezes and adhere to the transfer surface.
Implementation Method 2
The precooled water is directed into a plurality of dispensing heads. The bands of water come into contact with a transfer surface as they are formed. The transfer surface is actively cooled. When the water bands contact the transfer surface, the water partially freezes
Data Source
AI summary
A 3D printing system for producing an object from ice. Precooled water is directed into dispensing heads. The dispensing heads produce bands of water in patterns that are governed by a 3D model. The water droplets come into contact with an actively cooled transfer surface. The water bands partially freeze and adhere to the transfer surface. The transfer surface is on a track, belt, or drum that moves the partially frozen water bands into positions for use. The transfer surface is connected to a positioning system that can move the transfer surface and the semi-frozen bands of water. The positioning system moves the transfer surface causing the bands of water to be brought into contact with a surface of the object being formed. Upon contact with the object being formed, the bands of water fully freeze into ice bands that adhere to the object being formed.