Thermoset 3D Printing with Real-Time Perturbation Correction
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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 due to defects in individual layers, while attempts to use thermosetting resins result in low-quality parts with poor resolution control and frequent clogging issues.
Innovation Solution
A 3D printing process involving a thermoset printing apparatus with a mixing chamber, extrusion nozzle, actuator, and scanner to detect perturbations in layers and adjust deposition parameters based on a perturbation profile, allowing for the production of high-resolution and durable thermosetting resin objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting resins are used in FFF printing, then material durability and strength are improved, but resolution control deteriorates and clogging issues increase
Solution Approach 1:
The patent changes the physical state parameter of the thermosetting resin from liquid monomer to a more viscous pre-polymer or oligomer state, allowing it to be extruded without flowing or breaking into droplets. This parameter change enables the use of thermosetting materials while maintaining resolution control and preventing clogging issues.
Solution Approach 2:
The patent performs preliminary polymerization to convert liquid monomers into pre-polymers or oligomers before extrusion. This preliminary action transforms the material properties in advance, enabling controlled extrusion and deposition without the flowing and droplet formation problems that occur with liquid monomers.
2Ease of manufacture
If traditional FFF methods are used, then ease of manufacture is maintained, but manufacturing precision deteriorates due to layer defects
Solution Approach 1:
The patent incorporates a scanner that detects perturbations in deposited layers and feeds this information back to the control system, which then adjusts deposition parameters in real-time. This feedback mechanism maintains manufacturing precision by correcting layer defects while preserving the relative simplicity of the FFF manufacturing process.
Solution Approach 2:
The patent makes the deposition process dynamic by continuously adjusting deposition parameters based on real-time scanner feedback. This dynamic adjustment allows the system to adapt to layer variations and maintain high manufacturing precision without significantly complicating the manufacturing process.
3Adaptability or versatility
If multiple layers are printed, then object complexity and functionality are improved, but manufacturing precision deteriorates due to cumulative defects
Solution Approach 1:
The patent uses continuous scanner feedback during multi-layer printing to detect and correct perturbations as they occur. This real-time feedback ensures that each layer is deposited with the correct parameters, preventing cumulative defects and maintaining resolution consistency throughout complex multi-layer objects.
Solution Approach 2:
The patent performs preliminary detection and adjustment before defects can propagate to subsequent layers. By scanning and adjusting parameters in real-time during the printing process, the system prevents small perturbations from accumulating into significant manufacturing errors in complex multi-layer structures.
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, precise edges, and improved durability by detecting and correcting dimensional defects in real-time, enhancing the overall quality and consistency of the printed parts.
Implementation Method 1
scanning the layer of thermosetting resin to detect a perturbation
Implementation Method 2
an extrusion nozzle to deliver the thermosetting resin to form a 3D object
Implementation Method 3
a mixing chamber into which a plurality of components comprising a first reactive component and a second reactive component are directed and contacted to produce an extrudable thermosetting resin
Data Source
AI summary
A three-dimensional (3D) object and a 3D object production process is disclosed comprising depositing the thermosetting resin along the deposition path during at least a portion of which the thermosetting resin is produced and deposited according to the one or more deposition parameters to form one or more layers of the thermosetting resin according to the predefined design; scanning at least a portion of the one or more of the deposited layers of the thermosetting resin to detect one or more perturbations present therein, which differ from the predefined design to form a perturbation profile; adjusting the one or more deposition parameters of one or more subsequent layers based the perturbation profile; and depositing the subsequent one or more layers of thermosetting resin according to the adjusted deposition parameters to form the 3D object according to the predefined design.