Thermoset 3D Printer Dynamic Material Control
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Solution Overview
Problem
Conventional 3D printing technologies using thermoplastic materials are limited in achieving desired material attributes and properties, such as durability and resolution, due to their inability to dynamically control material properties during the printing process.
Innovation Solution
A computer system dynamically controls a thermoset 3D printer by accessing a material attribute dataset to determine specific mixture configurations of thermoset materials, adjusting flow rates and tool paths to achieve desired final material properties, such as surface properties, through the use of multiple extruders and coreactive components that form covalent bonds between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermoplastic materials are used in conventional 3D printing, then the printing process is simple and fast, but the material attributes and durability cannot be dynamically controlled
Solution Approach 1:
The system dynamically adjusts material composition by controlling the flow rates of multiple thermoset materials in real-time during the printing process. The computer system modifies mixture ratios based on the specific printing stage and desired material properties, enabling dynamic control of material attributes rather than using fixed composition materials.
Solution Approach 2:
The invention changes the physical and chemical parameters of the material by controlling the curing process. Thermoset materials are deposited in uncured or partially cured states with adjustable viscosity and reactivity, then cured in-situ through UV light or heat to achieve desired final properties. This allows parameter changes during printing to optimize both speed and material control.
2Reliability
If thermoset materials with dynamic control are used, then material attributes and durability are improved, but the system complexity increases
Solution Approach 1:
The computer system serves multiple functions: it controls the extrusion of multiple materials, manages the curing process, adjusts flow rates dynamically, and stores material property data. By consolidating these control functions into a single multi-functional system, the patent reduces overall system complexity despite the increased capability to handle multiple materials and processes.
Solution Approach 2:
The computer system acts as an intermediary between the multiple thermoset materials and the final printed object. It coordinates the interaction between materials with different properties, controlling their deposition and curing to achieve desired outcomes. This intermediary control simplifies the management of complex material interactions.
3Manufacturing precision
If multiple thermoset materials are mixed in specific ratios, then desired final material properties are achieved, but the material selection and configuration become more complex
Solution Approach 1:
The system performs preliminary actions by pre-programming material property data and mixture configurations in the computer system before printing begins. The material attribute dataset stores information about different thermoset material combinations and their resulting properties, allowing the system to automatically select and configure appropriate mixtures without requiring complex real-time adjustments or manual material selection.
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 creation of stronger, more durable 3D objects with improved mechanical and electrical properties, such as solvent resistance and thermal resistance, by dynamically controlling the material attributes during the printing process.
Implementation Method 1
coreactive components that form covalent bonds between layers
Implementation Method 2
controlling the flow rates and tool paths of the coreactive components
Data Source
AI summary
A computer system for dynamically controlling a thermoset printer (100) may comprise one or more processors (210) and one or more computer-readable media having stored thereon executable instructions that when executed by the one or more processors, configure the computer system to perform various acts. The computer system may receive a thermoset printing data packet that comprises an indication of a desired final material property of the target object to be printed. The computer system may also receive an indication of one or more thermoset materials (250a,250b) that are available to the thermoset three-dimensional printer and access a material attribute dataset that describes different material properties. Based upon the material attribute dataset, the computer system may determine a particular mixture configuration for the one or more thermoset materials and generate a command to cause the thermoset three-dimensional printer to implement the particular mixture configuration.