3D Printing Binder Composition for Faster Layer Bonding
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Solution Overview
Problem
Existing 3D printing methods using solvent-based or radiation-hardening binder systems face issues such as solvent volatility leading to component weakness, geometric deviations, print head damage, environmental hazards, and inefficient production speeds due to incomplete layer bonding.
Innovation Solution
A binder system comprising a thermally secondary cross-linkable prepolymerisate and alcohol-based solvent, combined with selective heating after every second to seventh layer application, ensures stable layer bonding and avoids aggressive solvents, reducing the risk of print head damage and enhancing production speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a solvent-based binder system is used, then the binder can be easily applied and particles can be bound, but the solvent volatility causes component weakness, geometric deviations, and print head damage
Solution Approach 1:
The invention changes the fundamental parameter of the binder system from solvent-based to water-based, altering the evaporation characteristics and chemical properties to eliminate the harmful effects of volatile organic solvents while maintaining the binder's functionality
Solution Approach 2:
The invention uses a biodegradable, environmentally friendly binder system that can be easily disposed of without causing environmental harm, replacing the persistent and harmful solvent-based systems
2Strength
If radiation-hardening systems are used, then layer bonding can be achieved, but complete hardening delays the build process and excessive irradiation prevents layer bonding
Solution Approach 1:
The invention implements periodic heating cycles during the build process, applying heat at specific intervals to promote progressive binder curing and interlayer bonding without requiring continuous high-energy irradiation, thus maintaining both bond strength and production speed
Solution Approach 2:
The invention utilizes thermal phase transitions and heat-activated binder curing mechanisms to achieve layer bonding, replacing radiation-hardening systems and allowing controlled solidification without the drawbacks of excessive irradiation
3Strength
If heating is applied after every layer application, then layer bonding is improved, but production speed decreases
Solution Approach 1:
The invention applies heating periodically rather than continuously, with optimized heating cycles that provide sufficient thermal energy for binder curing while minimizing total heating time and maintaining high production speed
Solution Approach 2:
The invention maintains continuous build process operation with optimized heating intervals, ensuring that layer bonding occurs efficiently without interrupting the overall production flow, thus maintaining high productivity
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 approach achieves high unpacking strength, edge sharpness, and faster production by minimizing solvent evaporation effects, allowing for continuous machine operation and reduced material and personnel risks, while maintaining component quality.
Implementation Method 1
The solvent is only slowly released from the dissolved material... After the solvent evaporates, the particles stick together
Implementation Method 2
selective heating after every second to seventh layer application... the applied layer or layers is/are subjected to a heat treatment
Implementation Method 3
A binder system comprising a thermally secondary cross-linkable prepolymerisate... ensures stable layer bonding
Data Source
AI summary
The invention relates to a method, a device and a binding agent system for producing three-dimensional models.