3D Printing Binder Chemistry for Stronger Interlayer Particle Bonding
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Solution Overview
Problem
Current three-dimensional printing technologies face challenges in effectively bonding solid particles across layers, leading to incomplete or weak interlayer adhesion, which affects the structural integrity and durability of printed articles.
Innovation Solution
The use of a liquid binder comprising a 1,1-di-activated vinyl compound or its multifunctional form, which infiltrates between solid particles and reacts to solidify, forming a cross-linked binder that bonds both individual layers and stacks of layers in three-dimensional printing, enhancing interlayer adhesion and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional liquid binders are used in three-dimensional printing, then the printing process can be completed, but the interlayer adhesion is weak and structural integrity is compromised
Solution Approach 1:
The patent changes the chemical parameters of the binder by using 1,1-di-activated vinyl compounds with specific reactivity characteristics. These compounds have two electron-withdrawing groups on the same carbon atom, creating highly reactive vinyl groups that form strong covalent bonds with solid particles and between layers, directly addressing the weak interlayer adhesion problem while maintaining structural integrity.
Solution Approach 2:
The patent creates a composite binder system by combining 1,1-di-activated vinyl compounds with solid particles (such as glass beads, metal powders, or ceramic particles). This composite approach allows the reactive binder to penetrate and bond with the particles, forming a unified structure where the binder and particles work together to achieve both strong interlayer adhesion and overall structural integrity.
2Strength
If conventional binders are used, then layers can be bonded, but the bonding is incomplete and weak
Solution Approach 1:
The patent modifies the chemical reactivity parameters of the binder through the use of 1,1-di-activated vinyl compounds. The dual electron-withdrawing groups create highly reactive vinyl groups that rapidly polymerize and form complete, thorough bonds with all solid particles in the layer, ensuring no incomplete bonding regions and achieving uniform bonding strength throughout the printed structure.
3Adaptability or versatility
If traditional printing methods are used, then articles can be produced, but additional support structures are required for complex geometries
Solution Approach 1:
The patent changes the mechanical properties of the binder through chemical composition modification. The 1,1-di-activated vinyl compounds form rigid, strong bonds that can support overhanging and complex geometric features without additional support structures, enabling direct printing of complex geometries by altering the binder's bonding parameters rather than adding support infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method produces monolithic and integral three-dimensional articles with improved bonding between cross-sectional layers, resulting in enhanced mechanical properties, such as increased strength and resistance to water and organic solvents, while allowing for complex geometries without additional support structures.
Implementation Method 1
The liquid binder comprises a 1,1-di-activated vinyl compound, or a multifunctional form thereof, or a combination thereof. The gaps between the solid particles are infiltrated with the liquid binder in the predetermined area of the layer of solid particles to form a first cross-sectional layer of an article. The 1,1-di-activated vinyl compound, or multifunctional form thereof, or combination thereof, is reacted to solidify the liquid binder and bind the solid particles in the first cross-sectional layer of the article.
Implementation Method 2
The use of a liquid binder comprising a 1,1-di-activated vinyl compound or its multifunctional form, which infiltrates between solid particles and reacts to solidify, forming a cross-linked binder that bonds both individual layers and stacks of layers in three-dimensional printing
Data Source
AI summary
A process for producing an article by three-dimensional printing includes applying a 1,1-di-activated vinyl compound-containing liquid binder over a predetermined area of a layer of solid particles. The liquid binder infiltrates gaps between the solid particles to form a first cross-sectional layer of an article, and the 1,1-di-activated vinyl compound reacts to solidify the liquid binder and bind the solid particles in the first cross-sectional layer of the article. Also provided is an article produced by the three-dimensional printing process, set forth herein.