3D Printing Techniques for Complex Object Shapes

A system for 3D printing objects with embedded electrical pathways and components. The system uses pretreatment ink, conductive ink, and fusing ink that is compatible and balanced to allow conductive structures to form within the printed parts. The pretreatment ink contains metal chloride salts that remove dispersing agents from the conductive ink. This allows the conductive particles to sinter together when heated during printing. The conductive ink contains transition metals that absorb light to heat the ink. The fusing ink contains agents that also absorb light and heat the ink.

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Additively manufacturing magnetically enabled parts with customizable magnetic profiles that are not limited by the shape and composition of the part. The system uses magnetically permeable material that can be selectively concentrated in regions to create a bi-material part with unique magnetic properties. The additive manufacturing process allows freedom in design and geometry to create magnetically enabled parts like solenoids, rotors, and stators with unusual shapes and performance.

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3D printing silicone elastomer articles with complex shapes using water-based supports that can be easily removed and recycled. The method involves 3D printing a silicone elastomer with a cross-linkable composition and support with a composition containing nano clay and water. The clay-water support is compatible with the silicone printing material and allows for printing complex shapes. The support can be dissolved and reused after printing.

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Hydraulic valve components are manufactured via additive processes like 3D printing to provide a geometry that fine-tunes their various functions. The components include features like lattices, meshes, asymmetric shapes, undercut apertures, and varying aperture sizes to enhance valve performance compared to conventionally machined components. Additive manufacturing allows the creation of complex customized shapes that optimize flow areas, forces, stability, and metering characteristics.

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A 3D printed filter medium that can be manufactured with complex geometries and porosity to improve filtration efficiency and capacity. The filter is made layer-by-layer using 3D printing techniques with controlled movement patterns to create porous structures optimized for filtering fluids. The layering pattern can vary within the filter to gradually decrease pore size downstream to trap particles better.

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Polishing the inner wall of a 3D-printed metal part with a complex-shaped hollow structure. An electrochemical polishing method is used to overcome the limitations of traditional machining. The process involves printing the metal part with a coaxial cathode inside. After sealing the cavity, the inner wall is electrochemically polished using the cathode. Finally, the cathode is broken to remove it and obtain a polished metal part. This allows uniform polishing of the inner walls of complex-shaped 3D-printed metal parts that cannot be effectively machined.

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Selective electrodeposition and electroetching device and method for additive manufacturing and selective etching of three-dimensional models with complex structures. The device uses a wheel with a layered photoconductive surface that forms an electrode pattern when selectively illuminated. An ionic liquid layer is maintained between the wheel and a conductive platform holding the model. The localized electric field between the illuminated wheel electrodes and platform electrode allows precise selective electrodeposition or etching.

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Creating 3D structures of defined geometries for cell culture and tissue engineering using a dynamically tunable yield stress material. The method involves causing a phase change in a region of the yield stress material using focused energy and then displacing the material in the region with a second material like cells or hydrogel. This allows 3D printing of complex shapes directly in the yield stress material. The advantage is the yield stress material can be temporarily liquefied for printing and then re-solidify to support the structure. This allows the creation of custom 3D cell culture scaffolds without complex 3D printing equipment.

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A method for 3D printing complex-shaped metal or ceramic parts with full density and high mechanical properties. The method involves creating a sacrificial powder mold of the complex shape using a swellable binder. The mold is filled with unsintered powder and subjected to high pressure. After densification, the powder part is sintered to full density, and the sacrificial mold naturally self-destructs during sintering. This allows complex parts to be fabricated without complex tooling or debinding steps.

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Creating complex 3D finite element mesh models of irregular bodies for analysis and fabrication. The method involves slicing a 3D mapping of the body into horizontal layers, creating elements within each slice, and connecting common nodes between adjacent slices. This produces a linked hexahedral element mesh that approximates the complex body geometry.

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A method for efficiently and easily forming complex 3D objects, particularly organ models for medical training, using inkjet-style printing. The method involves using two liquids: one liquid forms the soft organ-like structure and the other forms a removable support material. The organ material contains a hydrogel precursor complexed with a water-dispersible mineral. The support material contains a curable monomer. Both liquids are jetted in layers and cured with UV light. The support material is then dissolved away, leaving behind the precise 3D object. This allows complex organs with internal structures to be formed without specialized equipment for support removal.

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