Thermoset 3D Printing with Lead-In and Lead-Out Blocks
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Solution Overview
Problem
Existing 3D printing technologies using thermoplastics face limitations such as single material property printing, limited print-direction strength, durability, and softness, while thermosetting materials result in low quality and resolution due to viscosity issues and clogging, and starting or ending a printing layer causes quality issues.
Innovation Solution
The use of lead-in and lead-out block layers connected by bridges in the 3D printing process to stabilize flow and pressure, allowing for smooth finish, high resolution, and precise edges in objects made from thermosetting materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermosetting materials are used in FFF printing, then material property versatility is improved, but printing quality and resolution deteriorate due to viscosity issues and material flow problems
Solution Approach 1:
The patent applies preliminary action by depositing a lead-in block layer before the main part layer. This lead-in block serves as a preparatory structure that allows the thermosetting material to flow and stabilize before reaching the actual printing area, preventing viscosity-related quality issues while enabling the use of versatile thermosetting materials.
Solution Approach 2:
The lead-in block layer acts as an intermediary between the material flow system and the main printing area. It mediates the material flow by providing a transition zone where the thermosetting material can adjust its flow characteristics, thereby maintaining both material versatility and printing quality.
2Productivity
If printing layers are started or ended during 3D printing, then productivity is improved, but object quality deteriorates due to layer transition issues
Solution Approach 1:
The lead-in bridge layer serves as an intermediary connection between the lead-in block and the main part. This bridge structure allows for smooth material flow transitions during layer changes, enabling frequent layer starts and ends without compromising object quality, thus maintaining both productivity and manufacturing precision.
3Device complexity
If thermosetting materials are used without lead-in blocks, then device complexity is reduced, but material flow stability and pressure control worsen
Solution Approach 1:
The patent segments the printing process into distinct layers: lead-in block layer, lead-in bridge layer, main part layer, lead-out bridge layer, and lead-out block layer. This segmentation allows each layer to serve a specific function in stabilizing material flow and pressure, achieving flow stability without significantly increasing device complexity.
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 enables the production of 3D objects with smooth finishes and precise edges by stabilizing flow and pressure during printing, overcoming issues associated with thermosetting materials and layer transitions.
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
The lead-in block can be printed in parallel to the main part when it is connected to the main part through a bridge of material. This process allows the flow rate and pressure in the tip to stabilize before printing the main part.
Data Source
AI summary
A three-dimensional (3D) object and a 3D object production process 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 thermosetting material, an extrusion nozzle to deliver the thermosetting material to form a 3D object, at least one actuator coupled to the extrusion nozzle to move the extrusion nozzle when delivering the thermosetting material to form the 3D object, and a controller comprising one or more processors and coupled to the extruded thermoset printing apparatus, and depositing the thermosetting material to form the 3D object, wherein the depositing comprises depositing a lead-in block layer of thermosetting material, depositing a lead-in bridge layer of thermosetting material, depositing a main part layer of thermosetting material, depositing a lead-out bridge layer, and depositing a lead-out block layer.