3D Printing Organic Solvent Plasticizer Viscosity
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Solution Overview
Problem
Current 3D printing technologies face challenges in achieving consistent high-density parts due to thermal inhomogeneities and narrow temperature processing windows, which can result in part inconsistency and reduced mechanical properties.
Innovation Solution
Incorporating an organic solvent plasticizer into the jettable fluid, which reduces the melt viscosity and melting temperature of the polymeric build material, allowing for a wider temperature processing window and improved selectivity of voxels, thereby enhancing the fusing and density of parts even at lower temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional 3D printing methods are used without organic solvent plasticizer, then the process is simpler, but the temperature processing window is narrow and part consistency is poor
Solution Approach 1:
The patent applies parameter changes by introducing an organic solvent plasticizer that modifies the thermal properties of the polymeric build material. Specifically, the plasticizer reduces the melting temperature and extends the temperature processing window, allowing for a broader range of acceptable processing temperatures. This resolves the contradiction by improving part consistency through expanded thermal parameters while maintaining a relatively simple inkjet-based application process
Solution Approach 2:
The organic solvent plasticizer acts as an intermediary substance between the electromagnetic radiation absorber and the polymeric build material. It mediates the thermal processing by reducing melt viscosity and enabling more uniform heating, thereby improving voxel selectivity and part consistency without requiring complex equipment modifications
2Manufacturing precision
If higher temperatures are used to improve fusing, then density improves, but the risk of over-fusing increases and small features lose resolution
Solution Approach 1:
The patent changes the thermal parameters of the build material by incorporating an organic solvent plasticizer, which reduces the melting temperature and extends the processing window. This allows achieving adequate fusing density at lower temperatures, thereby preventing over-fusing damage while maintaining voxel selectivity and small feature resolution
Solution Approach 2:
The patent applies local quality by using an electromagnetic radiation absorber that is selectively deposited only in the regions requiring fusing. Combined with the plasticizer's viscosity reduction effect, this ensures that heating is localized precisely where needed, achieving high density in printed regions without affecting surrounding areas and preserving small feature integrity
3Manufacturing precision
If the temperature processing window is narrow, then energy use is lower, but manufacturing precision and part consistency deteriorate
Solution Approach 1:
The patent expands the temperature processing window parameter through the use of organic solvent plasticizer, which reduces melt viscosity and melting temperature. This broader window improves voxel selectivity and manufacturing precision while allowing for more flexible energy input conditions, ultimately enabling consistent part quality without excessive energy consumption
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 use of organic solvent plasticizer extends the temperature processing window, enabling the production of high-density parts with greater consistency and flexibility, reducing the risk of over-fusing and improving the resolution of small features within the printed objects.
Implementation Method 1
Incorporating an organic solvent plasticizer into the jettable fluid, which reduces the melt viscosity and melting temperature of the polymeric build material
Implementation Method 2
selectively jetting an electromagnetic radiation absorber and an organic solvent plasticizer onto a first portion of the layer of polymeric build material... directing electromagnetic radiation to the layer of polymeric build material to cause the radiation absorber at the first portion to raise a temperature
Data Source
AI summary
A three-dimensional printing system can include polymeric build material and jettable fluid(s). The polymeric build material can have an average particle size from 20 μm to 150 μm, a first melt viscosity, and a melting temperature from 75° C. to 350° C. In one example, the jettable fluid can include water, from 0.1 wt % to 10 wt % of electromagnetic radiation absorber, and from 10 wt % to 35 wt % of an organic solvent plasticizer. Contacting a first portion of a layer of the polymeric build material with the jettable fluid can provide an organic solvent plasticizer loading from 2 wt % to 10 wt % based on the polymeric build material content. The first melt viscosity of the polymeric build material at the first portion can be reduced and the melting temperature of the polymeric build material at the first portion can be decreased by 3° C. to 15° C.