3D Printing Composite Material Reducing Thermal Expansion
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Solution Overview
Problem
Current 3D printing technologies face challenges in achieving enhanced mechanical properties and dimensional stability of printed objects, particularly at elevated temperatures, due to limitations in material adhesion and thermal expansion issues.
Innovation Solution
A composite 3D printing build material composition is developed, comprising a polymer particle with low melting temperature and low melt viscosity, combined with an inorganic particle of high melting temperature, which rapidly wets and embeds into the polymer phase during the printing process, forming a continuous polymer phase with embedded inorganic particles, thereby improving mechanical properties and reducing thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional 3D printing materials are used, then the printing process is simple, but the mechanical properties and dimensional stability of printed objects deteriorate at elevated temperatures
Solution Approach 1:
The patent applies composite materials by combining polymer particles with inorganic particles to create a build material that exhibits reduced thermal expansion and improved mechanical properties at elevated temperatures, directly resolving the contradiction between temperature resistance and dimensional stability
Solution Approach 2:
The patent changes the physical and chemical parameters of the build material by selecting polymer particles with specific melting temperatures and inorganic particles with specific surface properties, creating a composite that maintains dimensional stability under thermal stress
2Strength
If inorganic particles are added to polymer particles, then mechanical properties and thermal stability are improved, but material adhesion and wetting become more difficult
Solution Approach 1:
The patent changes the surface parameter of inorganic particles by selecting particles with specific surface chemistry that are wettable by melted polymer, enabling good adhesion while maintaining the mechanical property enhancements from the inorganic reinforcement
Solution Approach 2:
The patent applies local quality by ensuring the inorganic particles have specific surface properties (wettability) that facilitate localized bonding with the polymer matrix, while the bulk properties of the inorganic particles provide mechanical reinforcement
3Productivity
If polymer particles with low melting temperature are used, then printing speed is maintained, but thermal expansion increases
Solution Approach 1:
The patent uses composite materials where inorganic particles with low thermal expansion are embedded in the polymer matrix, creating a composite that maintains the low melting temperature and printability of the polymer while the inorganic phase reduces the overall coefficient of thermal expansion
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 composite material exhibits increased stiffness and reduced coefficient of thermal expansion, leading to enhanced mechanical properties and dimensional stability of 3D objects, without the need for compatibilizers and with minimal impact on printing speed.
Implementation Method 1
the inorganic particle material has a high melting temperature (e.g., typically above 1000°C) and a surface that is wettable by the melted polymer particle
Implementation Method 2
the polymer particle is an aliphatic polyamide having a low melting temperature (e.g., from about 80°C to about 300°C) and a low melt viscosity
Implementation Method 3
The viscosity of melt polymers is dependent on temperature. In an example, the melt viscosity of the polymer particle (at operating temperatures ranging from about 180°C to about 200°C) during a 3D build ranges from about 50 Pa·s (pascal-second) to about 350 Pa·s
Data Source
Figure 1
Figure 2~3B
Figure 3C~3D
AI summary
A three-dimensional (3D) printing composite build material composition includes a polymer particle and an inorganic particle. The polymer particle is an aliphatic polyamide. The inorganic particle has an average particle size ranging from about 1 µm to about 100 µm. A mass ratio of the polymer particle to the inorganic particle in the composite build material composition ranges from about 5:2 to about 1:3.