3D Binder System With Selective Heating for Faster Stronger Parts
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Solution Overview
Problem
Existing 3D printing methods using powdered materials face issues such as slow solvent evaporation leading to weak components, geometric deviations, and risks to the print head due to aggressive solvents or monomers, as well as delays in the build process with radiation-hardening systems.
Innovation Solution
A binder system comprising a novolak or resol system with a solvent, where selective heating is applied after every second or additional layer application, using a thermally secondary cross-linkable prepolymerisate and alcohols or water as solvents, and incorporating additives like tensides and antifoaming agents to achieve stable and strong components without aggressive solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solvent-based binding system is used, then the particles can be dissolved and stuck together in desired locations, but the solvent evaporation is slow leading to weak components and long waiting periods
Solution Approach 1:
The patent changes the physical-chemical parameters of the binding system by replacing solvent-based dissolution with a dual-component chemical reaction system. The first component contains reactive groups that undergo condensation or addition reactions with the second component, transforming the binding mechanism from physical dissolution to chemical cross-linking, thereby achieving rapid strength development without long waiting periods
Solution Approach 2:
The invention utilizes the phase transition from liquid monomers/oligomers to solid cross-linked polymer network. The reactive components are applied in liquid form for easy deposition, then undergo rapid polymerization to form strong solid bonds, eliminating the slow evaporation phase required in solvent-based systems
2Strength
If aggressive solvents or monomers are used for binding, then the particles can be effectively bound, but the print head is at risk of damage
Solution Approach 1:
The patent modifies the chemical parameters of the binding system by selecting monomers and oligomers with low aggressiveness toward print head materials. The reactive groups are chosen to be chemically milder while maintaining high reactivity for cross-linking, thus protecting the print head from damage while achieving effective particle binding
Solution Approach 2:
The invention introduces a two-component system where the reactive groups act as intermediaries between the binder and particles. The first component contains functional groups that react with corresponding groups in the second component, mediating the binding process through controlled chemical reactions rather than direct contact with aggressive solvents or monomers
3Productivity
If radiation-hardening systems are used, then the build process can be accelerated, but layer bonding is delayed and complete hardening is required before any further processing
Solution Approach 1:
The patent segments the hardening process into multiple stages by using a dual-component system that can be activated progressively. Each layer receives a portion of the reactive components and undergoes partial cross-linking, with subsequent layers building upon previously bonded layers, allowing continuous processing without requiring complete hardening of the entire structure
Solution Approach 2:
The invention applies preliminary binding action by incorporating reactive groups that begin cross-linking immediately upon contact, providing initial layer adhesion before complete hardening. This preliminary action allows subsequent layers to be applied and bonded without waiting for full curing of previous layers
4Ease of manufacture
If solvent-based systems are used, then the components can be removed after unpacking, but deposit buildup occurs on components and manual removal is required
Solution Approach 1:
The patent changes the physical parameters of the binding system by using a low-viscosity dual-component system that penetrates particles effectively but evaporates or cures without leaving significant residues. The reactive components are formulated to minimize deposit formation while maintaining ease of component removal from the build platform
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 components with high unpacking strength and edge sharpness, reduces the risk of print head damage, and allows for continuous machine operation, while minimizing material and personnel hazards and environmental risks, with faster production speeds and reduced material costs.
Implementation Method 1
a thermally secondary cross-linkable prepolymerisate
Implementation Method 2
selective heating is applied after every second or additional layer application
Implementation Method 3
The solvent evaporates, the particles stick together in the desired locations
Data Source
AI summary
The invention relates to a method, a device and a binding agent system for producing three-dimensional models.