3D Shaping Powder Composition for Uniform Laser-Sintering Feed
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Solution Overview
Problem
Existing powder materials for selective laser sintering 3D printers using powder bed fusion method face issues with uneven surface and internal structure due to the inability to successfully feed materials, particularly those containing cellulose nanofibers, leading to defects in the shaped articles.
Innovation Solution
A powder material comprising a resin and cellulose material with a specific particle size distribution, including a cumulative frequency of particles between 100 to 300 µm of 30% or more, and a cellulose content of 2.0 to 30.0 mass%, which allows for uniform feeding and improved mechanical properties in the shaped articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass beads are mixed with resin powder to improve strength, then the strength of the shaped article is improved, but the specific gravity increases causing the article to be heavier
Solution Approach 1:
The patent changes the material parameter from glass beads to cellulose nanofibers, which have different physical properties (lower specific gravity, higher strength-to-weight ratio). This substitution maintains or improves strength while reducing the weight of the shaped article.
Solution Approach 2:
The patent creates a composite material system using cellulose nanofibers combined with resin powder. This composite approach leverages the high strength and low density characteristics of cellulose nanofibers to achieve both improved strength and reduced weight compared to glass bead composites.
2Strength
If glass beads are mixed with resin powder to improve strength, then the strength is improved, but the specific gravity difference between glass beads and resin causes uneven strength distribution
Solution Approach 1:
The patent changes the size parameter of the reinforcing material to nanoscale (cellulose nanofibers), which significantly reduces the size difference between the reinforcement and the resin matrix. This minimizes settling and aggregation effects, leading to more uniform distribution and consistent strength throughout the shaped article.
3Strength
If glass beads are mixed with resin powder to improve strength, then the strength is improved, but glass recycling becomes impossible
Solution Approach 1:
The patent enables material recovery and recycling by using cellulose nanofibers instead of glass beads. Cellulose-based materials can be more easily recovered, separated, and recycled compared to glass bead composites, supporting circular economy principles and sustainable manufacturing.
4Manufacturing precision
If powder material with small particle size is used for PBF 3D printing, then the surface finish is improved, but the feeding process becomes problematic causing unevenness in the shaped article
Solution Approach 1:
The patent optimizes the particle size parameter of the powder material to achieve a balance between surface finish quality and feeding process reliability. By carefully controlling particle size distribution and morphology, the material achieves good layer formation and surface finish while maintaining顺畅 feeding through the 3D printing system.
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 proposed powder material enables successful feeding and production of three-dimensionally shaped articles with an even surface and enhanced mechanical properties, such as flexural modulus and strength, using selective laser sintering 3D printers.
Implementation Method 1
powder bed fusion (PBF), one including sintering a powder by laser is particularly called selective laser sintering/melting (SLS/SLM)
Implementation Method 2
sintering a powder by laser
Implementation Method 3
sintering a powder by laser is particularly called selective laser sintering/melting (SLS/SLM)
Data Source
Figure 1
Figure 2~3
AI summary
Provided is a powder material for three-dimensional shaping which comprises: a resin suitable for three-dimensional shaping with a powder bed fusion type laser-sintering 3D printer, and a cellulose material. The powder material for three-dimensional shaping comprises a powder containing both a resin and a cellulose material, the content of the cellulose material being 2.0-30.0 mass%. In volume-based particle diameters of the particles constituting the powder, the cumulative frequency of particles of 100-300 µm is 30.0% or greater.