3D Printed Thermal Expansion Structure for Mass Production
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Solution Overview
Problem
Current 3D printing techniques are limited by curing time, making them inefficient for mass production and unsuitable for producing complex structures, leading to high production costs and inefficiencies.
Innovation Solution
A 3D printed thermal expansion structure is created using a mixture of thermoplastic and thermal expansion materials, processed by a 3D printing apparatus and heated to expand proportionally, allowing for the production of complex structures while reducing manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional 3D printing technique is used to produce complex structures, then the ability to create intricate designs is improved, but the curing time increases and production efficiency decreases
Solution Approach 1:
The patent applies preliminary action by pre-mixing thermoplastic material with thermal expansion material before 3D printing. This pre-prepared mixed material allows the printed structure to undergo thermal expansion immediately after printing, eliminating the need for separate curing time and enabling rapid production of complex structures.
Solution Approach 2:
The patent utilizes parameter changes by controlling the thermal expansion properties of the material. By adjusting the composition ratio of thermoplastic to thermal expansion material and controlling heating parameters, the structure achieves rapid dimensional change without extended curing time, thereby improving production efficiency while maintaining complex geometry.
2Productivity
If conventional molding method is used for mass production, then production efficiency is improved, but the ability to create complicated structures decreases
Solution Approach 1:
The patent achieves universality by creating a material system that combines both 3D printing capability and thermal expansion functionality. The mixed material of thermoplastic and thermal expansion material can be printed directly into complex shapes and then rapidly expanded, enabling mass production of complicated structures without requiring separate molding processes.
Solution Approach 2:
The patent employs composite materials by combining thermoplastic material with thermal expansion material in a mixed formulation. This composite material retains the shape-defining capability of thermoplastic while adding rapid thermal expansion properties, allowing mass production of complex structures that would traditionally require time-consuming molding processes.
3Device complexity
If 3D printing technique is used without thermal expansion material, then manufacturing process is simplified, but the manufacturing time for mass products cannot be reduced
Solution Approach 1:
The patent utilizes phase transitions by incorporating thermal expansion material that undergoes rapid dimensional change when heated. This phase transition occurs immediately after printing, eliminating the need for extended curing or post-processing time, thereby significantly reducing manufacturing time for mass products while keeping the process relatively simple.
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 enables the production of complex structures with significantly reduced manufacturing time, enhancing the efficiency of 3D printing for mass production while maintaining the ability to create intricate designs.
Implementation Method 1
a solid object which is formed by the 3D printing apparatus could expand proportionally during the heating process to form the 3D printed thermal expansion structure
Data Source
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AI summary
A 3D printed thermal expansion structure (20) includes a thermoplastic material (12) and a thermal expansion material (14), wherein the thermoplastic material (12) is in a range from 50 to 90 wt% based on a weight of the 3D printed thermal expansion structure (20), and the thermal expansion material (14) is in a range from 10 to 50 wt% based on the weight of the 3D printed thermal expansion structure (20). The thermoplastic material (12) and the thermal expansion material (14) are mixed to form a mixed material, and the mixed material is utilized by a 3D printing apparatus (1) to form a solid object (10), and the solid object (10) is heated to form the 3D printed thermal expansion structure (20). A manufacturing method of a 3D printed thermal expansion structure (20) is provided herein.