3D-Printed Thermoplastic Parts Post-Processing Deformation
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Solution Overview
Problem
Current 3D printing methods for aerospace applications face challenges in producing complex, load-bearing components that are both cost-effective and sustainable, while ensuring optimal mechanical properties and structural integrity.
Innovation Solution
A method combining 3D printing with post-processing deformation techniques, such as bending or heat treatment, to reorient the layered structure of 3D-printed parts made from thermoplastic materials, enhancing mechanical properties and allowing for the creation of lightweight, complex shapes that can withstand principal tension loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If selective laser sintering is used to produce parts with advantageous mechanical properties, then the mechanical strength and reliability are improved, but the energy consumption and production cost increase considerably
Solution Approach 1:
The patent applies parameter changes by modifying the post-processing conditions (temperature, time, pressure) to achieve the desired mechanical properties. By optimizing these parameters, the process attains improved mechanical strength comparable to selective laser sintering while consuming significantly less energy during the actual printing phase.
Solution Approach 2:
The patent employs preliminary action by performing the energy-intensive heating and deformation operations as post-processing steps after the low-energy 3D printing is complete. This allows the bulk material to be deposited efficiently first, then only the necessary portions are subjected to intensive thermal and mechanical treatment to achieve final mechanical properties.
2Use of energy by stationary object
If fused deposition modeling is used to produce parts at low cost and with low energy usage, then the production cost and energy consumption are reduced, but the mechanical properties and layer connection strength show anisotropy
Solution Approach 1:
The patent applies parameter changes by implementing controlled thermal and mechanical parameters during post-processing. Heating the printed part to specific temperatures and applying controlled deformation forces reorients the layered structure and enhances inter-layer bonding, thereby improving mechanical properties while maintaining the low energy advantage of fused deposition modeling.
Solution Approach 2:
The patent employs dynamics by introducing controlled deformation and reorientation of layers through mechanical forces during post-processing. This dynamic treatment transforms the static anisotropic layered structure into a more isotropic configuration with improved mechanical strength, while the process itself consumes minimal additional energy.
3Adaptability or versatility
If 3D printing is used to create complex objects with intricate shapes, then the design flexibility and geometric freedom are improved, but the mechanical stability and structural integrity may be compromised
Solution Approach 1:
The patent employs preliminary action by creating the complex geometric shape through low-energy 3D printing first, preserving design flexibility. Then, as a subsequent preliminary step before final use, controlled deformation and heat treatment are applied to reinforce the structure, ensuring mechanical stability is achieved without compromising the intricate geometry.
Solution Approach 2:
The patent applies local quality by targeting specific regions of the printed object for deformation and heat treatment. Rather than uniformly treating the entire object, the process focuses on critical load-bearing areas and layer interfaces, thereby improving mechanical stability where needed while maintaining the overall complex geometry and design flexibility.
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 enables the production of weight-saving, complex objects with improved mechanical stability at reduced costs and energy use, facilitating sustainable manufacturing for aerospace components.
Implementation Method 1
locally introducing heat into the 3D-printed part or causing heat to be locally generated or released in or on the 3D-printed part
Implementation Method 2
causing deformation of the 3D-printed part in such a manner that a shape of a main surface of extension of the layers is modified
Data Source
Figure 1A~1C
Figure 1D~1F
Figure 2A~2B
AI summary
A method of producing an object (11a, 11b-16b, 11c, 11d, 11e, 11f, 12f, 11g, 11h), the method comprising: 3D-printing (S2) a part (1a-1e, 1f, 1f', 1g-1i, 1k, 1m, 1n) or at least a portion thereof in layers (101-105); and post-processing (S3) the 3D-printed part to obtain the object. The post-processing includes causing deformation (S34) of the part in such a manner that a shape of a main surface of extension (SE) of the layers is modified. Furthermore the disclosure relates to an object (11a, 11b-16b, 11c, 11d, 11e, 11f, 12f, 11g, 11h) produced or producible using such a method, and to an aircraft or spacecraft (1000) comprising such an object.