3D Printing Thermal Control for Deformation Reduction
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Solution Overview
Problem
3D printing often results in deformation of objects during or after the printing process, requiring auxiliary supports that increase manufacturing costs and time, and can hinder the creation of complex designs like hanging structures or cavities.
Innovation Solution
The method involves using a defocused energy beam to form large tiles on a material bed, which are then translated and overlapped to create a 3D object without auxiliary supports, allowing for control over microstructure and material properties, and includes a system for planarizing the material bed without contact to manage deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If auxiliary supports are inserted to prevent deformation during 3D printing, then the structural stability is improved, but the manufacturing cost and time increase
Solution Approach 1:
The patent applies preliminary action by pre-heating the build plate and controlling the thermal environment before and during the printing process. This preliminary thermal preparation prevents deformation without requiring auxiliary supports, thereby maintaining structural stability while avoiding the time loss associated with support insertion and removal
Solution Approach 2:
The patent replaces the mechanical support system with a thermal control system. Instead of using physical auxiliary supports to prevent deformation, the system uses controlled heating and temperature management to maintain structural stability, eliminating the need for mechanical interventions that会增加 manufacturing time
2Stability of the object's composition
If auxiliary supports are used to prevent deformation, then the structural stability is improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces mechanical auxiliary supports with a thermal field-based approach. By using controlled heating zones and temperature management, the system achieves structural stability without requiring additional physical support materials, thereby reducing manufacturing costs
Solution Approach 2:
The patent changes the thermal parameters (temperature, heating rate, zone distribution) during the printing process to prevent deformation. This parameter control approach eliminates the need for auxiliary supports and associated material costs while maintaining structural integrity
3Adaptability or versatility
If traditional layer-by-layer additive process is used, then the manufacturing flexibility is improved, but the productivity decreases
Solution Approach 1:
The patent segments the heating process into multiple independent zones with different temperature controls. This allows simultaneous processing of different regions with optimized parameters, increasing productivity while maintaining the flexibility to handle complex geometries and material variations
Solution Approach 2:
The patent implements continuous heating and processing without interruption between layers. The thermal field remains active throughout the printing process, eliminating idle time between layer deposits and significantly increasing manufacturing speed while preserving design flexibility
4Productivity
If high power energy beam is used to form layers quickly, then the productivity is improved, but the material bed deformation increases
Solution Approach 1:
The patent segments the energy beam application into multiple lower-power zones that process different regions simultaneously. This distributed approach maintains high overall productivity while preventing localized overheating and deformation of the material bed
Solution Approach 2:
The patent uses periodic scanning motion of the energy beam across the material bed. This periodic action distributes thermal energy evenly over time, preventing heat concentration that would cause deformation while maintaining efficient processing speed
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 approach reduces deformation, eliminates the need for auxiliary supports, and enables the creation of complex designs by controlling microstructure and material properties, while also allowing for efficient removal of excess material in sensitive environments.
Implementation Method 1
irradiating an exposed surface of the material bed using an energy beam directed at a first position of the exposed surface that is substantially stationary during a first time-period of at least one millisecond, to transform the pre-transformed material at the first position to a transformed material
Implementation Method 2
transform the pre-transformed material at the first position to a transformed material to form a first tile
Data Source
AI summary
The present disclosure various apparatuses, and systems for 3D printing. The present disclosure provides three-dimensional (3D) printing methods, apparatuses, software and systems for a step and repeat energy irradiation process; controlling material characteristics and/or deformation of the 3D object; reducing deformation in a printed 3D object; and planarizing a material bed.