Fused Filament Fabrication (FFF) suffers from weak interlayer bonding, delamination and warping because the material cools down after being deposited.
Orion AM uses thermal radiation, the heat penetrates through the material, allowing the layers to truly fuse together. This results in parts that are more uniform in strength, more dense and stronger.
With pictures, Orion AM shows it is able to increase the strength in the z-direction 10 times (https://www.orion-am.com/thermal-radiation-heating) .
I am not surprised it is possible, but impressed by the proof they gave.
Adam Rumjahn filed a patent US20210387401A1. The first 11 claims have been withdrawn.
Adam outlines it is key to match the spectrum of the IR source with the absorbance spectrum of the filament. I can imagine that a lot of heat is absorbed at the interface between the layers.
The following figure is from the patent.
In reality this looks a follows;
I think laser scanning or a laser could add a lot of value here. I want to claim the following and add to the public domain.
The material would be deposited with fused filament fabrication. After deposition, a laser scanner would use IR or UV radiation to perfect the bonding between the layers. The laser scanner could use optical coherence tomography or simply look at the scattered light to monitor the bonding process. Key seems to be that the heat penetrates through the part and heats up the interface.
An alternative would be to apply the laser radiation prior to fused filament or liquid deposition.
I can imagine that using a laser to heat up the previous layer before a layer is placed on top of it could also work. This might simplify things as it does not needs to penetrate through the previous
layer.
In a preferred embodiment, the laser head is integrated with the fused filament deposition head.
I assume that the laser heating process is much faster than the deposition.
Naturally, the whole process takes place in a heated build chamber. The advantage of using a laser scanner would be that you can more precisely apply and monitor the addition of IR or UV radiation. You could better control the fusing process.
Besides the applications outlined by Orion AM a very good application could be glass printing.
Delamination is a big issue here as it make the resulting glass structure not uniform. This is very apparent. So here heating the previous layer with a power full laser before extrusion of the glass, might also fix the de-lamination issue.
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