Elastic Materials for 3D Printing

Method for optimizing 3D printed part properties by dynamically generating the print path and material extrusion amounts based on user-defined center-of-gravity and weight information. The method involves acquiring designation data for the 3D object's center-of-gravity and weight, generating print models with extrusion paths and amounts based on that data, and then controlling the printer to follow those models. This allows customizing the print to balance factors like stability, warpage, and support requirements based on the object's properties.

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A method and device for 3D printing complex shapes without support structures. The method involves dividing the suspended surfaces of the 3D model into subregions on a 2D plane. The subregions are scanned and melted layer by layer using parallel melting lines. The division directions change layer by layer to prevent overlapping. This allows printing suspended surfaces without supports by transitioning smoothly to non-suspended areas. The device implements this method for unsupported 3D printing.

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A method for improving the quality of material extrusion 3D printing by using fluid mechanics simulation to accurately predict the shape of the deposited extruded wire for different process parameters. The method involves constructing a phase change material model with viscosity-temperature correspondence and simulating the extrusion process from melting to solidification. This allows more accurate contour fitting compared to using a single fixed profile, especially for high temperature, high performance materials. The simulation results can be used to optimize process parameters and reduce deviations in wire shape.

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A method for 3D printing items using semi-crystalline polymers like polyethylene that prevents warping and adhesion failures during printing. The method involves selectively cooling and heating the build plate and printed layers to optimize crystallization and melting. This allows the semi-crystalline polymers to adhere to the plate during printing and then solidify for strength. The steps include: 1) depositing the polymer on the plate at a high temperature to melt it and adhere it. 2) cooling the deposited layers below their crystallization temperature. 3) raising the plate temperature to below the polymer's melting point. 4) continuing printing with the higher plate temperature and lower layer temperature to prevent warping and adhesion failures. 5) removing the printed item at room temperature. This sequence enables the semi-crystall

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Method for defining the material properties of plastic parts during 3D printing to enable on-demand customization of properties like stiffness, strength, and toughness. The method involves actively varying extrusion parameters like temperature, flow rate, and nozzle diameter during printing to manipulate the microstructure of the extruded material. This allows selective modification of properties in specific regions of the printed part. The technique involves using a 3D printer with features like variable nozzle diameter, temperature control, and speed variators to enable real-time adjustment of extrusion parameters. By varying parameters like temperature and flow rate at different locations, the method allows inducing specific microstructures and hence tailored properties in those regions.

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High-precision 3D printing of viscoelastic paste materials like ceramic slurries using a customized printing system. The system uses a movable build plate instead of a fixed one to enable precise layer-by-layer printing of viscoelastic pastes. An extruder deposits paste onto the plate, followed by a scraper to level it. This improves accuracy compared to full-layering methods. The plate moves up/down for each layer. A conveyor belt cleans the scraper. The system has components like clamps, motors, belts, rails, etc. to enable the customized printing process.

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A porous structural body made of flexible resin or rubber configured to increase friction between split bone parts when compressed to deform. The body has a skeleton throughout with split bone parts that rub against each other when compressed. This increases friction compared to continuous bones. The split bone parts are non-parallel, inclined, or surrounded to enhance rubbing. The friction adjustment allows tuning dynamic characteristics like cushioning response.

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Reducing warpage and making it easier to separate 3D printed objects from the build plate. The method involves using a different material for the initial layer compared to subsequent layers. This initial layer integrates with the build plate to reduce warping. Then using a different material for the subsequent layers allows easier separation as the initial layer holds the object to the build plate. This avoids needing a release agent or excessive force to remove the object.

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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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Foam particles are used in additive manufacturing (3D printing) to make articles like athletic equipment. The method involves arranging foam particles of thermoplastic elastomers and using energy beams like lasers to selectively heat and fuse the foam particles together. This allows the article to be constructed layer by layer.

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Multi-axis 3D printer and printing method that allows for high-precision printing of complex parts with variable cross-sections. The printer has a multi-axis motion platform connected to a material extrusion device. The control system extracts cross-sectional data from the 3D model and generates motion commands for the platform based on that data. This enables coordinated movement between the extruder and platform to print lines with adjustable widths and heights, avoiding issues like step errors and missing features. The variable cross-sections improve printing quality for complex shapes.

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Body-mounted components like orthoses have improved flexibility and resistance to breakage when bent. The components are made by 3D printing using a resin material with high elongation at break when stretched. This elongation property allows the 3D-printed parts to bend and stretch without breaking.

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3D printed structures made from liquid crystal elastomers that can change shape in response to environmental stimuli. The structures are printed using stereolithography and have segments in different orientations to enable 3D-to-3D shape change. To achieve this, liquid crystal alignment is controlled during printing using magnetic fields.

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3D printing of elastomeric rubber seals using a 3D printer with two print heads. The first head extrudes the rubber material, which is heated and mixed in an extruder like a screw to cure it partially. The extruder is also heated. The second head prints a support structure of a more rigid material around the rubber layers to prevent sagging. The rubber layers are printed on a heated bed.

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Method to produce low warpage and high precision 3D printed parts using polyaryletherketone (PAEK) materials like PEEK and PEKK. The method involves blending PEEK and PEKK resins with different melting points to create a composite filament. This composite filament is used to print the 3D part. The blended resins have different crystallization rates that helps regulate the crystallization during printing to reduce warping. The part is then machined using small feed rates and high speeds to further reduce internal stresses. Finally, annealing is done to eliminate residual stresses and further reduce warpage.

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Customizable vehicle cushion components made using 3D printing with lattice structures of interconnected 3D cells. The lattice cells in the cushion can have different geometries and elastic moduli to achieve varying levels of support and comfort. For example, face-centered cubic lattice cells can provide higher modulus support, while body-centered cubic cells can provide lower modulus cushioning. The lattice sections can be integrated into a single monolithic structure.

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Customizable 3D printed trim articles, like headrest buns, are made from a lattice matrix with tunable elastic modulus. The lattice is 3D printed with additive manufacturing techniques. The lattice is printed in sections, and the curing time of each section is adjusted to vary its stiffness. Longer curing times increase the elastic modulus of the lattice. The overall lattice can be customized for different stiffness regions by printing sections with different curing times and moduli.

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Self-adaptive matrix extrusion method for 3D printing that reduces microscopic pores and improves mechanical strength of printed parts without changing the printing path. The method determines the optimal matrix extrusion amount at each print point based on the geometric spacing between points. By adjusting the matrix extrusion for overfilled and underfilled areas, it allows self-adaptive extrusion matching the print path. This reduces porosity and enhances part strength.

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Method for 3D printing objects with customizable shapes and properties by using an insertion needle to introduce the printing material into a support material. The key differences compared to traditional 3D printing are: 1. The printing material is introduced into the support material instead of being deposited on top of it. 2. The printing path can follow the geometry of the object without slicing into layers. 3. The printing speed is increased by depositing the entire wall thickness in one pass instead of layer by layer. 4. The wall thickness is modulated by changing the needle velocity and path distance. 5. The wall is formed by either completely surrounding the material or having it on one side. Multiple strands may be needed for thick walls. 6. The printing path can be continuous instead of back and forth to avoid abrupt changes. 7. Walls can be made of different materials by using separate print passes.

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High yield stress ceramic stereolithography 3D printing material with self-supporting force that allows complex ceramic parts to be printed without the need for contact supports. The material composition includes acrylate compounds, plasticizers, initiators, ceramic powders, dispersants, and polyamide waxes. The unique formulation enables ceramic powders with high volume fractions of 55-70% while still providing self-support for 3D printing without collapsing or sagging. This enables non-contact support strategies for complex structures without needing to remove supports after printing which can damage the parts.

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