3D Printing Translucency via Plasticizer Jetting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D printing technologies face challenges in achieving rapid production speed, part consistency, and flexibility, particularly in creating objects with varying optical translucency, as existing methods struggle to control the fusion and crystallization processes effectively.
Innovation Solution
The method involves using multi-jet fusion (MJF) with a polymer build material and a jetting fluid containing an electromagnetic radiation absorber and a translucency-modulating plasticizer, applied layer by layer, to selectively fuse and coalesce polymer layers, allowing for the creation of objects with controlled optical translucency by varying the amount of translucency-modulating plasticizer applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If selective laser sintering or traditional 3D printing methods are used, then three-dimensional objects can be produced, but the ability to control optical translucency and achieve varying transmittance levels is limited
Solution Approach 1:
The patent applies local quality by selectively depositing translucency-modulating plasticizer at specific locations and concentrations within the printed object. Different regions receive varying amounts of plasticizer based on the digital model requirements, enabling some areas to be translucent while others remain opaque. This localized modification allows precise control over optical properties in different parts of the same object.
Solution Approach 2:
The patent utilizes parameter changes by varying the concentration of translucency-modulating plasticizer to achieve different optical transmittance levels. By adjusting the amount of plasticizer deposited (from 0.1% to 10% or higher concentrations), the system can continuously modify the optical properties of the polymer material, transitioning from opaque to translucent states in a controlled manner.
2Productivity
If rapid production speed is achieved through automated printing processes, then productivity increases, but the precision of fusion and crystallization control decreases
Solution Approach 1:
The patent applies preliminary action by pre-heating the polymer powder bed to a temperature just below the melting point before printing begins. This pre-conditioning of the material ensures that when the laser or heat source passes through, the fusion process occurs rapidly and uniformly. The plasticizer is also pre-mixed or pre-positioned in the powder, so that when heated, it immediately begins modulating translucency without requiring additional processing steps.
Solution Approach 2:
The translucency-modulating plasticizer serves as an intermediary substance that facilitates both the fusion process and the optical property control. As the plasticizer melts and distributes through the polymer matrix during printing, it simultaneously aids in uniform heating and fusion while creating the desired translucent regions. This dual-function intermediary enables rapid production without sacrificing precision.
3Illumination intensity
If the amount of translucency-modulating plasticizer is increased to achieve higher optical transmittance, then translucency improves, but the structural integrity and strength of the printed object may be compromised
Solution Approach 1:
The patent applies local quality by selectively applying translucency-modulating plasticizer only in specific regions where optical transmittance is required, rather than uniformly throughout the entire object. Critical load-bearing structures receive little or no plasticizer to maintain strength, while non-structural or aesthetic regions receive higher concentrations to achieve desired translucency. This spatially differentiated approach balances optical and mechanical requirements.
Solution Approach 2:
The patent utilizes composite materials by combining the base polymer with translucency-modulating plasticizer in varying ratios and distributions. The resulting material is a composite where the plasticizer-modified regions provide optical functionality while the unmodified or less-modified regions maintain structural integrity. This composite approach allows the object to simultaneously achieve both translucency and strength through material heterogeneity.
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 enables the production of three-dimensional objects with optical transmittance ranging from 5% to 80%, offering increased flexibility in achieving desired translucency levels and improving the definition and smoothness of printed edges.
Implementation Method 1
the absorbed light energy at the portion including the electromagnetic radiation absorber can be converted to thermal energy, causing the polymer build material to melt or coalesce
Implementation Method 2
due to the presence of translucency-modulating plasticizer some portions of a printed three-dimensional object can exhibit optical translucency ranging from about 5% to about 80%
Implementation Method 3
exposing the powder bed to electromagnetic energy to selectively fuse portions of individual layers of the polymer build material together
Data Source
AI summary
A three-dimensional printing method can include iteratively applying polymer build material as individual layers; based on a three-dimensional object model, selectively jetting an electromagnetic radiation absorber and a translucency-modulating plasticizer onto individual layers of the polymer build material; and exposing the powder bed to electromagnetic energy to selectively fuse portions of individual layers of the polymer build material together to form a three-dimensional object. The polymer build material can include from about 60 wt % to 100 wt % polymeric particles having an average particle size from about 10 μm to about 150 μm and a degree of crystallinity from about 2% to about 60%, to a powder bed. At the locations where the polymer build material includes jetted translucency-modulating plasticizer, the three-dimensional object can exhibit an optical transmittance from about 5% to about 80%.