INCREASED INTERLAYER ADHESION OF THREE-DIMENSIONAL PRINTED ARTICLES

• US 20160325487A1
• Filed: 02/24/2014
• Published: 11/10/2016
• Est. Priority Date: 02/24/2014
• Status: Abandoned Application

• Current Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Original Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Inventors: Miller, Seth A.
• Application Number:
  US15/109,833
• Publication Number:
  US 20160325487A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 2059/145 Atmospheric plasma
• CPC Class Codes: B29C 48/02 Small extruding apparatus, e.g. handheld, toy or laboratory extruders
• CPC Class Codes: B29C 48/155 Partial coating thereof
• CPC Class Codes: B29C 48/2528 Drive or actuation means for non-plasticising purposes, e.g. dosing unit
• CPC Class Codes: B29C 48/265 Support structures or bases for apparatus, e.g. frames
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 59/14 by plasma treatment plasma tubes per se H01J
• 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 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• 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 50/02 for controlling or regulating additive manufacturing processes

Abstract

Technologies are generally described to increase interlayer adhesion of a 3D printed article. A printhead of a 3D printing system may include an extrusion nozzle configured to deposit one or more polymer layers onto a substrate to form the 3D printed article. A microplasma source may be coupled to the extrusion nozzle and may be configured to treat a surface of the substrate or a surface of the deposited polymer layers with plasma from the microplasma. The plasma may include at least one reactive species that may oxidize the surface of the substrate or the surface of the deposited polymer layer upon treatment in order to increase the interlayer adhesion of the 3D printed article.

Claims

1. A method to increase interlayer adhesion of a three-dimensional (3D) printed article, the method comprising:

positioning an extrusion nozzle of a 3D printer along a path;

coupling a microplasma source to the extrusion nozzle such that the microplasma source is positioned along the path of the extrusion nozzle, wherein the microplasma source is positioned to either precede or follow the extrusion nozzle along the path;

depositing a polymer layer from the extrusion nozzle along the path onto a surface of a substrate to form the 3D printed article; and

treating the surface of the substrate or a surface of the deposited polymer layer with plasma from the microplasma source by applying a voltage between a ground reference and at least one of two electrodes positioned within the microplasma source to cause a plasma drop from the microplasma source onto the surface of the substrate or the surface of the deposited polymer layer.

2. The method of claim 1, further comprising:

supplying one or more gases to the microplasma source, wherein the one or more gases are activated to form at least one reactive species in the plasma that oxidizes the surface of the substrate or the surface of the deposited polymer layer to increase an interlayer adhesion.

5. The method of claim 1, wherein treating the surface of the substrate or the surface of the deposited polymer layer with plasma from the microplasma source comprises:

applying the voltage between the ground reference and the at least one of two electrodes positioned within the microplasma source to cause the plasma drop from the microplasma source onto a surface of a previously deposited polymer layer prior to a deposition of another polymer layer.

6. The method of claim 1, further comprising:

positioning the microplasma source from about 0.5 mm to about 1 mm above the surface of the substrate or the surface of the deposited polymer layer.

7. The method of claim 1, further comprising:

rotating the extrusion nozzle as the polymer layer is deposited to track changes in a polymer deposition.

8. The method of claim 1, further comprising:

incorporating the microplasma source into the extrusion nozzle to allow treatment of the polymer layer with the plasma as the polymer layer is deposited from the extrusion nozzle.

3-4. -4. (canceled)

9. A printhead, comprising:

an extrusion nozzle of a three-dimensional (3D) printer configured to deposit one or more polymer layers onto a surface of a substrate to form a 3D printed article; and

a microplasma source incorporated into the extrusion nozzle, the microplasma source configured to treat a surface of the substrate or a surface of a deposited polymer layer with plasma from the microplasma source as the one or more polymer layers are deposited from the extrusion nozzle.

10. The printhead of claim 9, further comprising two or more electrodes positioned within the microplasma source, wherein the microplasma source is configured to apply a voltage between a ground reference and at least one of the two or more electrodes to cause a plasma drop to be deposited from the microplasma source onto the surface of the substrate or the surface of each polymer layer.

15. The printhead of claim 9, wherein the microplasma source is a macro-scale dielectric barrier discharge (DBD) source, a microhollow plasma source, or a radio frequency (RF) plasma source.

17. The printhead of claim 15, wherein the microplasma source is composed of one or more silicon chips or two or more mated pieces of perforated aluminum.

18. The printhead of claim 9, wherein the microplasma source is configured to deposit plasma to the surface of the substrate or the surface of the deposited polymer layer with plasma that comprises at least one reactive species.

19. The printhead of claim 18, further comprising:

a gas source coupled to the microplasma source, wherein the microplasma source is further configured to pass through one or more gases received from the gas source in an open configuration to allow activation of the one or more gases to form the at least one reactive species.

20. The printhead of claim 18, further comprising:

a gas source coupled to the microplasma source, wherein the microplasma source is further configured to ionize one or more gases received from the gas source in a closed configuration to allow activation of the one or more gases to form the at least one reactive species.

21. The printhead of claim 18, wherein the at least one reactive species include a hydroxyl radical or nitrogen oxide radical.

11-14. -14. (canceled)

16. (canceled)

22. A system to increase interlayer adhesion of a three-dimensional (3D) printed article, the system comprising:

a deposition module comprising an extrusion nozzle of a 3D printer positioned along a path, the deposition module configured to deposit one or more polymer layers from the extrusion nozzle along the path onto a surface of a substrate to form a 3D printed article;

a treatment module comprising two or more microplasma sources coupled to the extrusion nozzle and positioned along the path of the extrusion nozzle such that a first of the two or more microplasma sources precedes the extrusion nozzle and a second of the two or more microplasma sources follows the extrusion nozzle, the treatment module configured to treat a surface of the substrate or a surface of the one or more deposited polymer layers with plasma from the two or more microplasma sources; and

a controller configured to coordinate operations of the deposition module and the treatment module during a fabrication of the 3D printed article.

23. The system of claim 22, wherein the treatment module further comprises two or more electrodes positioned within each of the two or more microplasma sources, wherein each of the two or more microplasma sources is configured to apply a voltage between a ground reference and at least one of the two or more electrodes to cause a plasma drop to be deposited from each of the two or more microplasma sources onto the surface of the substrate or the surface of the one or more deposited polymer layers.

25. The system of claim 23, wherein plasma drop deposited from the first of the two or more microplasma sources precedes a path of polymer deposition from the extrusion nozzle and a plasma drop deposited from the second of the two or more microplasma sources follows a path of polymer deposition from the extrusion nozzle.

26. The system of claim 22, wherein the two or more microplasma sources are further positioned from about 0.5 mm to about 1 mm above the surface of the substrate or a surface of a previously deposited polymer layer.

27. The system of claim 26, wherein the first of the two or more microplasma sources that precedes the extrusion nozzle is positioned higher above the surface of the substrate or the surface of the previously deposited polymer layer relative to the second of the two or more microplasma sources follows the extrusion nozzle.

28. The system of claim 22, wherein the two or more microplasma source are positioned separately from the extrusion nozzle.

24. (canceled)

29. (canceled)