3D Thermoset Printing With Offset Layers for Support-Free Overhangs
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Solution Overview
Problem
Existing 3D additive manufacturing methods face challenges with thermosetting materials due to low viscosity and curing issues, leading to poor resolution and clogging, while using supports for overhangs adds complexity and cost.
Innovation Solution
A thermoset printing apparatus with a mixing chamber, extrusion nozzle, and controller is used to deposit thermosetting material layers offset from each other, adjusting time per layer and flow rates to achieve high overhangs without supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support structures are used to enable overhang printing, then the object stability during printing is improved, but the device complexity and material cost increase
Solution Approach 1:
The invention removes the support structure element from the printing process entirely. By using thermosetting materials that cure during printing, the method extracts the stabilizing function from physical support structures and transfers it to the material's chemical curing process, enabling overhang printing without additional support components.
Solution Approach 2:
The invention changes the material parameter from thermoplastic to thermosetting material, which fundamentally alters the printing mechanism. The thermosetting material's ability to cure and harden during the printing process provides inherent stability for overhangs, eliminating the need for support structures and simplifying the overall printing process.
2Stability of the object's composition
If support structures are used for overhang printing, then the object stability is improved, but the material cost and removal difficulty increase
Solution Approach 1:
The invention removes the support structure element from the printing process entirely. By using thermosetting materials that cure during printing, the method extracts the stabilizing function from physical support structures and transfers it to the material's chemical curing process, enabling overhang printing without additional support components.
3Strength
If thermosetting materials are used in FFF printing, then the material durability is improved, but the printing resolution deteriorates due to low viscosity and curing issues
Solution Approach 1:
The invention changes the material parameter from thermoplastic to thermosetting material, which fundamentally alters the printing mechanism. The thermosetting material's ability to cure and harden during the printing process provides inherent stability for overhangs, eliminating the need for support structures and simplifying the overall printing process.
Solution Approach 2:
The invention applies preliminary action by pre-heating the thermosetting material to reduce its viscosity before extrusion. This preliminary heating action allows the high-viscosity thermosetting material to flow smoothly through the nozzle and be deposited with high resolution, after which it cures to provide the desired durability.
4Strength
If thermosetting materials are used in FFF printing, then the material durability is improved, but the printing process reliability deteriorates due to clogging
Solution Approach 1:
The invention applies preliminary action by pre-heating the thermosetting material to reduce its viscosity before extrusion. This preliminary heating action allows the high-viscosity thermosetting material to flow smoothly through the nozzle and be deposited with high resolution, after which it cures to provide the desired durability.
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
Enables the 3D printing of objects with significant overhangs by stabilizing the printing process and eliminating the need for additional supports, improving resolution and durability.
Implementation Method 1
prior to cure, the monomers are low viscosity liquids
Implementation Method 2
Upon deposition, the curing liquid flows or breaks into droplets
Data Source
AI summary
A three-dimensional (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 a 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 first layer of thermosetting material and depositing an at least second layer of thermosetting material, wherein the beads of thermosetting material in the at least second layer are offset from the beads of thermosetting material in the first layer.