Thermoset Resin Printing and Curing via Localized Stimulus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional manufacturing techniques for high-performance thermosets and composites are slow, labor-intensive, energy-intensive, and require complex molds and tooling, with limitations in curing speed and ambient conditions, and result in brittle parts with poor mechanical properties.
Innovation Solution
A method and device for simultaneous printing and curing of thermoset resin using a feeder and a stimulation source to apply heat, eliminating the need for ovens, autoclaves, and complex molds, by extruding thermoset resin and directing a stimulus, such as laser or infrared light, to fully cure the resin in situ, allowing for high-speed production of freeform structures without post-curing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional curing methods (ovens and autoclaves) are used to cure thermoset resin, then the resin is fully cured, but the process requires large equipment that scales with part size, consumes significant energy, and takes several hours
Solution Approach 1:
The patent applies localized heating through a heater that directs thermal energy specifically to the deposited resin layer rather than heating the entire oven chamber. This localized approach reduces overall energy consumption while maintaining effective curing of the resin at the application point
Solution Approach 2:
The patent replaces the conventional thermal curing system (large ovens and autoclaves requiring hours of heating) with a localized heating system that cures resin immediately during deposition. This substitution dramatically reduces both energy consumption and curing time by eliminating the need for large-scale thermal chambers
2Reliability
If conventional manufacturing techniques are used, then parts are cured properly, but the process is slow and labor-intensive requiring several hours for curing
Solution Approach 1:
The patent merges the deposition and curing operations into a single simultaneous process. The heater is positioned to cure the resin immediately after it is deposited from the feeder, eliminating the separate post-curing step and enabling continuous production without interruption
Solution Approach 2:
The patent replaces the slow conventional curing process (requiring large ovens operating for several hours) with immediate localized heating during deposition. This substitution enables real-time curing that matches the deposition speed, dramatically increasing production throughput
3Adaptability or versatility
If frontal polymerization is used to cure resin, then freeform structures can be created without molds, but the speed is limited by the polymerization rate and is affected by ambient temperatures
Solution Approach 1:
The patent changes the curing mechanism from chemical self-sustaining polymerization to externally controlled thermal heating. This parameter change allows the curing speed to be controlled by the heater and deposition rate rather than being limited by the resin's inherent polymerization rate and ambient temperature conditions
Solution Approach 2:
The patent replaces the chemical polymerization process with externally applied thermal heating. This substitution eliminates the limitations of frontal polymerization (speed constraints and ambient temperature sensitivity) while maintaining the ability to create freeform structures without molds
4Productivity
If UV-sensitive resin is used for 3D printing, then immediate curing after deposition is achieved, but the parts are brittle with poor mechanical properties and low photo curing conversion
Solution Approach 1:
The patent changes the resin type from UV-sensitive resin to thermally curable thermoset resin. This parameter change enables immediate curing during deposition (maintaining high productivity) while achieving superior mechanical properties, fracture toughness, and higher conversion rates characteristic of thermoset materials
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 energy-efficient, high-speed production of thermoset polymers and composites with improved mechanical properties, eliminating the need for complex molds and post-curing, and allowing for the creation of freeform structures with minimal energy input and no post-treatment requirements.
Implementation Method 1
directing a stimulus from a stimulation source toward a portion of the output thermoset resin that is downstream from the outlet of the feeder. The stimulus is configured to heat the portion of the output thermoset resin to fully cure the portion of the output thermoset resin
Implementation Method 2
the stimulus includes infrared light
Implementation Method 3
the resin must be cured at elevated temperatures (∼180° C.) for several hours
Data Source
AI summary
Various implementations include a method of printing and curing of thermoset resin. The method includes outputting a thermoset resin from an outlet of a feeder and directing a stimulus from a stimulation source toward a portion of the output thermoset resin that is downstream from the outlet of the feeder. The stimulus is configured to heat the portion of the output thermoset resin to fully cure the portion of the output thermoset resin.