3D Printing Composition Viscosity and Carbon Control
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Solution Overview
Problem
Existing three-dimensional modeled-object manufacturing methods face challenges in achieving high dimensional accuracy and desired physical properties due to issues with viscosity, binder residue, and carbon content, particularly when using compositions with high or low viscosity and binder content, which can lead to defects like sagging and corrosion resistance problems.
Innovation Solution
A three-dimensional modeled-object manufacturing composition and method utilizing particles with low carbon content, specifically metal or ceramic materials, and a binder system with controlled viscosity (η1 and η2) to ensure stable discharge and bonding, while minimizing binder residue and optimizing carbon content, using a composition with acrylic resin and polyester as the binder to achieve improved mechanical strength and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the viscosity of the composition is excessively high, then the composition can maintain shape stability, but the composition tends to be defectively discharged and dimensional accuracy decreases
Solution Approach 1:
The patent applies parameter changes by carefully controlling the viscosity of the composition within a specific range (10-100 Pa·s) to simultaneously achieve shape stability and proper dischargeability. The viscosity is adjusted by modifying the binder content and particle size distribution, allowing the composition to maintain its shape while being dischargeable without defects.
Solution Approach 2:
The patent employs local quality by using a mixed particle size distribution where fine particles fill gaps between coarse particles, creating localized density variations that improve green strength in critical areas while maintaining overall dischargeability. This local optimization allows different regions of the composition to have different properties tailored to their functional requirements.
2Ease of operation
If the viscosity of the composition is excessively low, then the composition is easily discharged, but unwilling deformation occurs due to sagging and dimensional accuracy decreases
Solution Approach 1:
The patent controls the viscosity parameter within the optimal range of 10-100 Pa·s to prevent sagging while ensuring easy discharge. This is achieved by adjusting the binder content and particle size distribution, creating a composition that flows easily during discharge but maintains its shape immediately after deposition.
Solution Approach 2:
The patent uses a composite material system combining particles of different sizes (fine and coarse particles) with a binder, creating a composite structure where fine particles act as a matrix holding coarse particles. This composite structure provides both ease of discharge and resistance to sagging, resolving the contradiction between dischargeability and shape stability.
3Strength
If a composition containing a binder is used for manufacturing, then the particles can be bound together, but an impurity derived from the binder is contained in the finally obtained three-dimensional modeled-object
Solution Approach 1:
The patent applies the extraction principle by using a binder system that can be completely removed or decomposed after serving its binding function. The organic binder provides necessary bonding strength during manufacturing but is subsequently eliminated through heat treatment or other removal processes, leaving no harmful impurities in the final green body.
Solution Approach 2:
The patent employs discarding and recovering by using a binder that is intentionally designed to be temporary and removable. The binder performs its binding function during the green body formation and is then discarded through controlled decomposition or removal processes, allowing the final product to be free from binder impurities while having achieved the necessary structural integrity during manufacturing.
4Strength
If particles with higher carbon content are used, then the mechanical strength may be improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by strictly controlling the carbon content parameter in the particles to be 0.10 mass% or lower. This parameter control ensures that the particles maintain sufficient mechanical strength while preventing excessive carbon content that would compromise corrosion resistance, particularly in stainless steel applications.
Solution Approach 2:
The patent uses local quality by selecting particles with specific material compositions and purity levels tailored to their intended function. High-purity particles with controlled carbon content are used in regions where corrosion resistance is critical, while maintaining overall mechanical strength through optimized particle size distribution and binder selection.
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 solution effectively enhances the dimensional accuracy and mechanical strength of the three-dimensional modeled-object, reduces binder residue, and improves corrosion resistance by controlling viscosity and carbon content, leading to more reliable and high-quality product formation.
Implementation Method 1
a solvent dispersing the particles
Implementation Method 2
a binder having a function of temporarily binding the particles in a state where the solvent is removed
Data Source
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AI summary
A three-dimensional modeled-object manufacturing composition used for forming a layer of a three-dimensional modeled-object in which a plurality of the layers is laminated, using a discharge method, the composition includes: a plurality of particles; a solvent dispersing the particles; and a binder having a function of temporarily binding the particles in a state where the solvent is removed. In the composition, a viscosity η1 at a shear rate of 10 s-1 at 25°C is 6,000 mPa·s or higher, a viscosity η2 at the shear rate of 1,000 s-1 at 25°C is 5,000 mPa·s or lower, and when a binder removal treatment is carried out by heating the composition at 400°C for five hours in nitrogen gas, a residual carbon ratio is 0.04 mass% to 0.3 mass%.