Thermoset 3D Printing Flow Control at Path Discontinuities
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Solution Overview
Problem
Existing 3D additive manufacturing methods using thermoplastics face limitations such as single material property printing, limited print-direction strength, and poor resolution, while attempts to use thermosetting materials result in low-quality parts due to flow issues and clogging, and existing solutions for discontinuities in printing paths lead to undesirable effects in the final object.
Innovation Solution
A 3D printing process involving a thermoset printing apparatus with a mixing chamber, extrusion nozzle, and controller that generates specific commands to manage the flow and translation of thermosetting material, including executing flow stop and reverse translation commands to address discontinuities and minimize material extrusion after stopping, thereby improving print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermosetting materials are used in FFF printing, then material property diversity and durability are improved, but the material flows or breaks into droplets upon deposition, resulting in low quality and low resolution
Solution Approach 1:
The patent changes the physical-chemical parameters of the thermosetting material by incorporating fillers (inorganic powders or polymers) to induce thixotropic behavior. This allows the material to maintain higher viscosity during deposition and then flow properly after deposition, resolving the contradiction between material versatility and print resolution
Solution Approach 2:
The patent creates composite thermosetting materials by combining resin with fillers such as inorganic powders or polymers. This composite formulation provides both the desired material properties and the necessary rheological behavior for high-resolution printing, eliminating the droplet formation issue
2Ease of operation
If fillers are added to thermosetting materials to induce thixotropic behavior, then material flow control is improved, but the final properties of the printed part are adversely affected
Solution Approach 1:
The patent carefully selects and optimizes the type, amount, and size of fillers to achieve thixotropic behavior while minimizing impact on final part properties. By controlling the filler concentration and characteristics, the material gains flow control capabilities without significantly compromising mechanical or physical properties of the printed part
3Loss of substance
If the printer stops depositing material at discontinuities, then material waste is reduced, but additional material continues to flow out of the nozzle, causing undesirable effects in the final object
Solution Approach 1:
The patent executes the flow stop command before the translation stop command at discontinuities, performing the flow cessation action in advance. This preliminary flow stop prevents additional material from flowing out of the nozzle after deposition stops, eliminating the quality defects caused by unwanted material extrusion at discontinuities
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
The process effectively manages thermosetting material flow to reduce undesirable effects from discontinuities, enhancing the quality and resolution of 3D printed objects by controlling the extrusion and translation of thermosetting materials during the printing process.
Implementation Method 1
a mixing chamber to receive and mix at least a first reactive component and a second reactive component to provide a thermosetting material
Implementation Method 2
an extrusion nozzle to deliver the thermosetting material to form a 3D object
Data Source
AI summary
A three-dimensional object production process and system comprising providing a thermoset printing apparatus comprising a mixing chamber to receive and mix at least a first reactive component and a second reactive component to provide a thermosetting material, an extrusion nozzle, at least one actuator coupled to the extrusion nozzle, and a controller, wherein the controller generates a printing path for the 3D printing process, executes a translation start command, a flow start command, a translation command, a flow command, a translation stop command, a flow stop command, and a reverse translation command to the thermoset printing apparatus during the 3D printing process, identifies an at least one discontinuity in the printing path, executes the flow stop command before the extrusion nozzle reaches the at least one discontinuity, executes the translation stop command before the at least one discontinuity, and executes a reverse translation command.