System for additive manufacturing of three-dimensional structures and method for same
Inventors
BEYER, Simon Travis • WALUS, Konrad • Mohamed, Tamer • BSOUL, Anas Amjad Mohammad
Assignees
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Publication Number
US-11738501-B2
Publication Date
2023-08-29
Expiration Date
Abstract
A system and method for additive manufacturing of three-dimensional structures, including three-dimensional cellular structures, are provided. The system comprises at least one print head for receiving and dispensing materials, the materials comprising a sheath fluid and a hydrogel, the print head comprising an orifice for dispensing the materials, microfluidic channels for receiving and directing the materials, fluidic switches corresponding to one of the microfluidic channels in the print head and configured to allow or disallow fluid flow in the microfluidic channels; a receiving surface for receiving a first layer of the materials dispensed from the orifice; a positioning unit for positioning the orifice of the print head in three dimensional space; and a dispensing means for dispensing the materials from the orifice of the print head.
Core Innovation
The invention relates to an additive-manufacturing system for printing three-dimensional structures using at least one print head having an orifice and at least two inlets arranged in respective microfluidic channels. The microfluidic channels include two first channels and two second channels that meet at intersection points and form a dispensing channel extending to the orifice.
The system is configured such that the third channel has a diameter less than each of the first channels and the dispensing channel, whereby flow of the at least one first material forms a coaxial sheath around the at least one second material in the dispensing channel upon printing. The receiving surface receives a first layer of materials dispensed from the orifice.
The receiving surface comprises a porous membrane with pores sized to permit passage of excess first material through. A fluid removal feature removes excess first material using an absorbent material or vacuum, and a positioning unit positions the orifice of the print head in three dimensional space, operably coupled to the print head.
Claims Coverage
The document provides one independent claim (clm-00001). Its coverage centers on a print head microfluidic channel geometry that produces a coaxial sheath flow at an orifice during additive manufacturing, combined with a porous receiving surface and a fluid removal feature, all positioned in three-dimensional space.
Microfluidic print head with coaxial sheath dispensing channel
The print head includes an orifice for dispensing at least one first material and at least one second material, with at least two inlets communicating with respective microfluidic channels arranged within the print head, where the microfluidic channels form a third channel and a dispensing channel such that flow of the at least one first material forms a coaxial sheath around the at least one second material in the dispensing channel upon printing.
Coaxial sheath focusing via diameter relationship
The third channel has a diameter less than each of the first channels and the dispensing channel, whereby coaxial sheath formation occurs in the dispensing channel during printing.
Porous receiving surface with pores for excess passage
A receiving surface receives a first layer of the materials dispensed from the orifice, wherein the receiving surface comprises a porous membrane comprising pores sized to permit passage of excess first material there through.
Fluid removal feature using absorbent material or vacuum
A fluid removal feature removes excess first material dispensed from the orifice, wherein the fluid removal feature comprises an absorbent material or a vacuum for drawing the excess first material away from or through the receiving surface.
Three-dimensional positioning unit for orifice positioning
A positioning unit positions the orifice of the print head in three dimensional space, the positioning unit operably coupled to the print head.
Dispensing means for dispensing from the orifice
A dispensing means dispenses the materials from the orifice of the print head.
Overall, the independent claim combines a specific microfluidic intersection and channel-diameter arrangement in a print head that creates coaxial sheath-like flow at an orifice, with a porous membrane receiving surface and a fluid removal feature using absorbent material or vacuum, all integrated with a three-dimensional positioning unit.
Stated Advantages
Not explicitly described in patent.
Documented Applications
The described uses include drug discovery.
The described compatibility includes well-plate formats (well-plate insert).
The described system includes throughput via multiple parallel print heads.
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