3D Printed Part Binder Redistribution to Prevent Warpage
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Solution Overview
Problem
The existing methods for producing three-dimensional shaped articles by stacking layers face issues with deformation due to biased distribution of solvent and binder, leading to stress and warpage during degreasing or sintering, caused by differential solvent volatilization rates across layers.
Innovation Solution
A method involving the formation of layers using a composition with powder, solvent, and binder, followed by thermal treatment at a temperature equal to or higher than the glass transition temperature of the binder, and subsequent degreasing or sintering, to reduce or eliminate stress and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layers are stacked by forming with composition containing powder, solvent, and binder, then three-dimensional shaped article can be produced, but stress is generated due to biased distribution of solvent and binder during volatilization
Solution Approach 1:
The patent applies a preliminary thermal treatment step before degreasing or sintering to redistribute the binder and eliminate stress. This preliminary action prevents the harmful effects of biased solvent and binder distribution that would otherwise cause warpage during subsequent processing, thereby maintaining shape accuracy while preserving production efficiency.
Solution Approach 2:
The patent changes the temperature parameter by heating the stacked layers to a temperature equal to or higher than the glass transition temperature of the binder. This parameter change enables the binder to flow and redistribute uniformly, eliminating stress concentrations that would lead to deformation during degreasing or sintering.
2Manufacturing precision
If thermal treatment is performed before degreasing or sintering, then stress is reduced and deformation is prevented, but production time increases
Solution Approach 1:
The patent merges the thermal treatment step with the existing degreasing or sintering process by performing thermal treatment at temperatures equal to or higher than the glass transition temperature of the binder during these necessary processing steps. This integration eliminates the need for separate thermal treatment steps, thereby preventing deformation without significantly increasing production time.
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 effectively reduces stress in the stack, prevents deformation, and increases production efficiency by minimizing the number of thermal treatment steps, while effectively handling multiple binder types and solvent distribution biases.
Implementation Method 1
performing a thermal treatment by applying heat at a temperature equal to or higher than a glass transition temperature of the binder to the layers obtained by performing the forming of the layers and the removing of the solvent
Implementation Method 2
removing the solvent contained in the layers
Implementation Method 3
performing heating to carry out at least one of degreasing and sintering with respect to a stack of the three-dimensional shaped article that has been thermally treated
Data Source
AI summary
Provided is a method for producing a three-dimensional shaped article in which the three-dimensional shaped article is produced by stacking a plurality of layers, and the method includes a layer formation step of forming layers by using a composition that contains a powder, a solvent, and a binder which constitute the three-dimensional shaped article, a solvent removal step of removing the solvent contained in the layers, a thermal treatment step of applying heat at a temperature equal to or higher than a glass transition temperature of the binder to the layers obtained by performing the layer formation step and the solvent removal step, and a heating step of carrying out at least one of degreasing and sintering with respect to a stack of the three-dimensional shaped article that has been thermally treated in the thermal treatment step.