3D Powder Bed Composition Using Polyol Stiffening Additives
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing 3D printing techniques using physical additives like fillers and fibers for altering properties face issues such as nozzle clogging and component wear, and hinder the fusing process, particularly in Multi Jet Fusion Printing (MJFP).
Innovation Solution
A 3D powder bed material comprising an elastomeric build material and a polyol stiffening additive with 3 to 7 carbon atoms, which enhances stiffness without fillers or fibers, improving Young's Modulus and tensile strength in the printed articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If physical additives like fillers and fibers are used to alter material properties, then mechanical strength and stiffness are improved, but nozzle clogging and component wear occur
Solution Approach 1:
The patent removes harmful physical additives (fillers and fibers) from the material composition entirely, extracting only the essential elastomeric polymer components that provide both structural integrity and printability without causing nozzle clogging or component wear
Solution Approach 2:
The patent changes the material parameters by using pure elastomeric polymers with controlled molecular weight and composition ratios, achieving enhanced mechanical strength through polymer chemistry rather than physical reinforcement, thereby avoiding the clogging issues associated with particulate fillers
2Strength
If physical additives like fillers and fibers are used to alter material properties, then stiffness is improved, but the fusing process is hindered
Solution Approach 1:
The patent achieves enhanced stiffness by modifying polymer composition parameters (using specific elastomeric polymers with controlled hardness ranges of 40-90 Shore A) rather than adding physical additives, allowing the material to maintain fusibility while achieving desired mechanical properties through molecular structure
Solution Approach 2:
The patent creates a composite-like effect by blending multiple elastomeric polymers with different properties (flexibility, strength, stiffness) in controlled ratios, achieving enhanced overall performance including stiffness without the manufacturing issues associated with traditional filler-reinforced composites
3Strength
If fillers and fibers are added to enhance mechanical properties, then strength and stiffness increase, but component wear and nozzle clogging increase
Solution Approach 1:
The patent completely extracts and eliminates fillers and fibers from the material formulation, relying solely on elastomeric polymers to provide mechanical strength, thereby removing the source of nozzle clogging and component wear problems
Solution Approach 2:
The patent converts the potential harm of needing mechanical reinforcement into a benefit by using the elastomeric polymers themselves to provide both flexibility and strength, turning what would be a compromise (adding fillers for strength) into an advantage (achieving strength without fillers)
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
The use of polyol stiffening additives in the 3D powder bed material results in 3D printed articles with increased stiffness and strength, achieving a Young's Modulus and ultimate tensile strength enhancement of up to 200% compared to articles without the additive, while avoiding nozzle clogging and wear issues.
Implementation Method 1
a polyol stiffening additive having 3 to 7 carbon atoms that is about 2 weight percent to about 20 weight percent of a total weight of the 3D powder bed material
Implementation Method 2
a fusing agent is applied to the 3D powder bed material, and the 3D powder bed material is fused to form a 3D printed article
Implementation Method 3
3D printing often uses curing or fusing of the building material, which for some materials is accomplished using heat-assisted extrusion, melting, or sintering
Data Source
AI summary
A polyol stiffening additive in a powder bed material for three-dimensional (3D) printing is disclosed herein. In an example, the 3D powder bed material includes an elastomeric build material and a polyol stiffening additive having 3 to 7 carbon atoms that is about 2 weight percent to about 20 weight percent of a total weight of the 3D powder bed material.