Optical Waveguide Feedstock for Uniform Photopolymer Curing
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Solution Overview
Problem
In 3D printing processes using photopolymers with reinforcing fibers, the opacity of fibers to curing energy prevents uniform curing due to shadowing, leading to incomplete or uneven polymer solidification.
Innovation Solution
Incorporating a full-length optical waveguide within the feedstock line that is covered by resin, allowing electromagnetic radiation to penetrate and cure the resin even in areas shaded by the fibers, through its end faces or peripheral surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing fibers are added to photopolymer feedstock material, then mechanical strength and structural integrity are improved, but the fibers cast shadows that prevent uniform curing of the photopolymer
Solution Approach 1:
The patent introduces a second light source positioned below the build platform, irradiating the feedstock line from the bottom dimension. This dual-directional approach (top and bottom light sources) enables uniform curing of the photopolymer throughout the feedstock line, including regions shadowed by reinforcing fibers when viewed from a single direction.
2Productivity
If direct electromagnetic radiation is used to cure the photopolymer, then the curing process is simple and rapid, but the radiation cannot penetrate shadowed regions blocked by opaque fibers
Solution Approach 1:
By adding a bottom light source that irradiates from the opposite direction, the system achieves complete curing without compromising speed. The dual-directional illumination ensures that radiation reaches all regions of the photopolymer, including those shadowed from the top view, thereby maintaining rapid curing while achieving complete penetration.
Solution Approach 2:
The patent uses the build platform and support structures as intermediaries to redirect and distribute electromagnetic radiation. The radiation reflects off these surfaces to reach shadowed regions, acting as a mediator that distributes curing energy uniformly throughout the feedstock line.
3Strength
If the feedstock line contains opaque reinforcing fibers, then the mechanical properties of the manufactured object are enhanced, but the electromagnetic radiation cannot reach interior regions of the feedstock line
Solution Approach 1:
The bottom light source irradiates from the opposite direction, enabling radiation to penetrate the feedstock line through the reinforcing fibers from below. This dual-directional approach ensures that interior regions receive sufficient energy for complete curing while maintaining the structural integrity provided by the fibers.
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
Ensures more even, thorough, and rapid curing of the resin within the feedstock line, suitable for additive manufacturing techniques like fused filament fabrication.
Implementation Method 1
At least the one full-length optical waveguide comprises a full-length optical core. The full-length optical core comprises a first full-length-optical-core end face, a second full-length-optical-core end face, opposite the first full-length-optical-core end face, and a full-length peripheral surface, extending between the first full-length-optical-core end face and the second full-length-optical-core end face.
Implementation Method 2
when electromagnetic radiation enters the full-length optical core via at least one of the first full-length-optical-core end face, the second full-length-optical-core end face, or the full-length peripheral surface, at least a portion of the electromagnetic radiation exits the full-length optical core via the full-length peripheral surface to irradiate, in the interior volume of the feedstock line, the resin
Implementation Method 3
When the polymer in the feedstock material is a photopolymer, a source of curing energy may be directed at the feedstock material, dispensed by the print head, to solidify the feedstock material.
Data Source
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AI summary
A feedstock line (100) comprises elongate filaments (104), a resin (124), and a full-length optical waveguide (102), comprising a full-length optical core (110). The full-length optical waveguide (102) is configured such that when electromagnetic radiation (118) enters the full-length optical core (110) via at least one of a first full-length-optical-core end face (112), a second full-length-optical-core end face (114), or a full-length peripheral surface (116) that extends between the first full-length-optical-core end face (112) and the second full-length-optical-core end face (114), at least a portion of the electromagnetic radiation (118) exits the full-length optical core (110) via the full-length peripheral surface (116) to irradiate, in an interior volume (182) of the feedstock line (100), the resin (124) that, due at least in part to the elongate filaments (104), is not directly accessible to the electromagnetic radiation (118), incident on the exterior surface (180) of the feedstock line (100).