Wet Dry 3D Printing With Solid Aggregate Materials
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Solution Overview
Problem
Conventional 3D printing technologies face limitations in creating objects with enhanced strength and flexibility due to the constraints of build volume and material integration, particularly in stereolithography processes where support structures are often required, leading to inefficiencies and imperfections.
Innovation Solution
A 3D printing system that alternately forms layers from photo-curable resin and solid aggregate materials, where the resin is partially cured and then physically coupled with the solid aggregate, such as fiberglass, to create a strong and flexible object, allowing for varied layer orientations and reduced need for temporary support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional stereolithography processes are used to build 3D structures layer by layer, then the manufacturing process can be automated and controlled digitally, but the objects require temporary support structures that lead to imperfections and reduce manufacturing efficiency
Solution Approach 1:
The patent combines photo-curable resin with solid aggregate materials (such as fiberglass, metal particles, or other reinforcement materials) to create composite layers. This composite approach allows the material itself to provide structural support and strength, eliminating the need for temporary support structures that cause imperfections. The solid aggregate materials are embedded within the cured resin matrix to form self-supporting layers.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the printing material by using partially cured resin with specific viscosity and adhesion properties. The resin is cured to a degree that provides sufficient structural integrity for layer support while maintaining enough flexibility for material impingement. This controlled partial curing state enables layers to support themselves without additional support structures.
2Device complexity
If conventional 3D printing processes use single materials, then the process is simpler, but the objects lack enhanced strength and flexibility characteristics
Solution Approach 1:
The patent employs composite materials consisting of photo-curable resin combined with solid aggregate materials such as fiberglass, carbon fiber, metal particles, or other reinforcement elements. These composite layers provide enhanced mechanical properties including increased strength, flexibility, and structural characteristics that cannot be achieved with single materials alone.
Solution Approach 2:
The patent enables different regions of the 3D object to have different material compositions and properties. By selectively varying the solid aggregate material content and type in different layers or regions, the object can exhibit locally optimized characteristics such as enhanced strength in load-bearing areas or flexibility in other regions.
3Stability of the object's composition
If conventional stereolithography uses fully cured resin layers, then the layers gain immediate structural integrity, but the layers cannot physically couple with solid aggregate materials through impingement
Solution Approach 1:
The patent performs preliminary partial curing of the resin layer to achieve an intermediate state with specific mechanical properties. This partial curing occurs before the solid aggregate material is introduced, creating a resin matrix that has sufficient cohesion to maintain layer integrity but retains the adhesion and viscosity characteristics needed for solid material impingement and coupling.
Solution Approach 2:
The patent applies partial curing rather than complete curing to the resin layer. This partial action approach provides just enough structural integrity for layer stability while leaving the resin in a state that allows effective physical coupling with solid aggregate materials. The curing process is deliberately stopped at an optimal intermediate point.
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
This method enables the creation of objects with improved structural characteristics, such as increased strength and flexibility, and larger build volumes, while minimizing the need for temporary support structures, thus enhancing the efficiency and quality of the 3D printing process.
Implementation Method 1
causing a first layer of the three-dimensional structure to be formed by partially curing a layer of the photo-curable resin
Implementation Method 2
the 3D printer may cause the base plate to push against the solid aggregate material so as to cause the solid to impinge at least partially into the partially-cured photo-curable resin
Implementation Method 3
the photo-curable resin may be fully cured so as to further mechanically couple the solid aggregate material to the resin matrix
Data Source
AI summary
A 3D printing process may form a 3D object by alternatingly forming layers from a liquid resin and a solid. For instance, when printing a 3D object, the 3D printer may at least partially cure a layer of liquid resin, and before the curing of the resin is complete, dip the semi-cured resin into a vat containing graphene powder so as to create a super strong 3D object. As another example, each semi-cured resin layer could be pressed into a vat of fiberglass such that the fiberglass is coupled to the semi-cured resin. The resin may then be allowed to finish curing before the next layer of resin is formed. In other embodiments, this process could be used to embed sensors in 3D printed objects.