Device and Method to Additively Fabricate Structures Containing Embedded Electronics or Sensors

• US 20150077215A1
• Filed: 04/26/2013
• Published: 03/19/2015
• Est. Priority Date: 04/26/2012
• Status: Abandoned Application

• Current Assignee: Northeastern University
• Original Assignee: Northeastern University
• Inventors: Ranky, Richard, Mavroidis, Constantinos, Sivak, Mark L., Carver, Alexandra, Landers, Daniel
• Application Number:
  US14/396,170
• Publication Number:
  US 20150077215A1
• Time in Patent Office: Days
• US Class Current: 338/47
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 70/88 characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29K 2505/08 Transition metals
• CPC Class Codes: B29K 2995/0003 having particular electrical or magnetic properties, e.g. piezoelectric
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: B29L 2031/34 Electrical apparatus, e.g. sparking plugs or parts thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H01C 10/10 adjustable by mechanical pressure or force
• CPC Class Codes: H05K 1/16 incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• CPC Class Codes: H05K 2201/0218 Composite particles, i.e. first metal coated with second metal
• CPC Class Codes: H05K 2201/0314 Elastomeric connector or conductor, e.g. rubber with metallic filler
• CPC Class Codes: H05K 2201/0323 Carbon
• CPC Class Codes: H05K 2201/0376 Flush conductors, i.e. flush with the surface of the printed circuit
• CPC Class Codes: H05K 2201/10151 Sensor
• CPC Class Codes: H05K 2203/0759 Forming a polymer layer by liquid coating, e.g. a non-metallic protective coating or an organic bonding layer
• CPC Class Codes: H05K 3/0014 : Shaping of the substrate, e.g. by moulding
• CPC Class Codes: H05K 3/0091 : Apparatus for coating printed circuits using liquid non-metallic coating compositions
• CPC Class Codes: H05K 3/1258 : by using a substrate provided with a shape pattern, e.g. grooves, banks, resist pattern

Abstract

A method of constructing an object includes depositing a first material in a predetermined arrangement to form a structure. The method further includes depositing a second material within the structure. The second material may have electrical properties and the method also includes providing electrical access to the second material to enable observation of the one or more electrical properties.

Claims

1. A method of constructing a object from a plurality of layers, comprising:

depositing a first material in a predetermined arrangement to form a first layer, wherein the depositing results in at least one channel occurring within the first layer;

depositing a second material within the at least one channel, the second material having one or more electrical properties;

depositing the first material in a predetermined arrangement to form a second layer, wherein the second layer covers at least a portion of the first layer; and

,

providing electrical access to the second material to enable observation of the one or more electrical properties.

2. The method of claim 1, wherein the depositing a first material further includes using an additive manufacturing technique.

3. The method of claim 1, wherein the depositing a second material further includes using an additive manufacturing technique.

4. The method of claim 1, wherein the predetermined arrangement further includes a plurality of consecutive layers, each of which is a cross-sectional profile of the sensor design.

5. The method of claim 1, wherein the second material includes a conductive elastomer, and the one or more electrical properties includes piezoresistive properties.

6. The method of claim 1, wherein the second material includes a room temperature vulcanizing silicone suspension of electrically conductive particles.

7. The method of claim 6, wherein the electrically conductive particles include nickel-coated graphite particles.

8. The object of claim 7, wherein the material includes graphite particles in a silicone RTV suspension.

9. An object comprising a plurality of consecutive layers wherein

the plurality of consecutive layers is produced using an additive manufacturing technique;

at least one layer with a first material defining one or more channels distributed therein,

a second material deposited within the one or more channels, wherein the second material is characterized by one or more electrical properties;

a first contact electrically coupled to a first location on the second material; and

,

a second contact electrically coupled to a second location on the second material.

10. The object of claim 9, wherein each of the plurality of consecutive layers is a cross-sectional profile of the object.

11. The object of claim 9, wherein the first location on the material is a first end of the material and the second location on the material is a second end of the material.

12. The object of claim 9, wherein the one or more electrical properties includes piezoresistive properties.

13. The object of claim 9, wherein the second material includes a room temperature vulcanizing silicone suspension of electrically conductive particles.

14. The object of claim 13, wherein the electrically conductive particles include nickel-coated graphite particles.

15. The object of claim 9, wherein the material includes graphite particles in a silicone RTV suspension.

16. A system for fabricating a three-dimensional object with electrical properties comprising

a build chamber;

a build platform disposed within the build chamber;

a deposition head disposed within the build chamber, configured to deposit a first material onto the build platform, and configured to deposit a second material with electric properties onto the build platform;

a memory for receiving data representing a three dimensional object;

a controller for forming a layer of material, adjacent to any last formed layer of material, accordance to the data representing the three dimensional object, operable to selectively control the deposition of the first and second material within the layer.

17. The system of claim 16 wherein the controller adjusts the relative position of the deposition head with respect to the build platform during fabrication.

18. The system of claim 16 further comprising

a reservoir capable of containing a material with electrical properties;

at least one motor assembly configured to impart a force on an actuator;

a controller configured to control the motor assembly;

a deposition nozzle in fluid contact with the interior of the reservoir;

wherein the actuator imparts a force on the material; and

wherein at least some portion of the material is expelled from the reservoir.

19. The system of claim 18 wherein the motor drives a lead screw and nut assembly.

20. The system of claim 18 wherein the motor drives a pinion of a rack and pinion system.

21. The system of claim 20 wherein the motor directly drives the pinion.

22. The system of claim 20 wherein the motor indirectly drives the pinion.

23. The system of claim 22 wherein the motor drives the pinion using a cable and pulley.

24. The system of claim 18 wherein the actuator is an auger.

25. The system of claim 18 wherein the system is attached to a 3D printer.

26. The system of claim 25 wherein the reservoir is directly mounted on the deposition head of the 3D printer.

27. The system of claim 25 wherein the reservoir is mounted on the exterior of the 3D printer.

28. The system of claim 27 wherein the deposition nozzle is mounted on the deposition head of the 3D printer.

29. The system of claim 28 wherein the deposition nozzle is connected to the reservoir using an impermeable tube.

30. The system of claim 28 wherein the reservoir is mounted on a mechanically grounded frame above the 3D printer.

31. The system of claim 30 wherein the reservoir is connected to the frame with a universal joint.

32. The system of claim 18 wherein the system is attached as a tool head on a numerically controlled or computer numerically controlled system.

33. The system of claim 18 wherein the system is attached to a drill press.

34. The system of claim 18 wherein the nozzle design reduces the force required to expel high viscosity material from the reservoir.

35. The system of claim 34 wherein the material has a viscosity higher than water.

36. The system of claim 18 wherein the environmental condition of the nozzle can be controlled by the controller.

37. The system of claim 18 wherein the nozzle design reduces the buildup of particles jamming.

38. The system of claim 36 wherein the environmental condition includes at least one of temperature or pressure.