3D Printing Preheat Subsystem for Polymer Feed
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Solution Overview
Problem
The speed of 3D printing processes is limited by the thermal response time of polymer feeds, leading to mechanical issues and thermal degradation, which results in reduced ductility and embrittlement of printed objects.
Innovation Solution
Preheating the polymer feed to a temperature above its glass transition temperature but below its melting point before processing, allowing for faster melting and reducing thermal degradation by increasing the polymer's mobility and processing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the polymer feed is heated quickly to increase processing speed, then the print speed increases, but thermal degradation occurs leading to chain scission and property deterioration
Solution Approach 1:
The patent applies preliminary action by preheating the polymer feed to the glass transition temperature (Tg) before the main heating to melting point. This preliminary heating step increases polymer mobility and reduces viscosity in advance, allowing the subsequent melting process to occur faster without causing thermal degradation. The preheating prepares the polymer chains for rapid processing by reducing their entanglement and increasing their freedom of movement before the high-temperature melting phase.
Solution Approach 2:
The patent utilizes parameter changes by heating the polymer feed to a specific temperature range (above Tg but below melting point) during the preheating phase. This temperature parameter change transforms the polymer from a rigid glassy state to a more mobile rubbery state, fundamentally altering its rheological properties. This parameter transformation enables faster subsequent processing while avoiding the harmful effects of excessive heating.
2Productivity
If the extruder temperature is increased to address feeding pressure issues, then the print speed can be increased, but filament decomposition occurs
Solution Approach 1:
The patent applies preliminary action by preheating the polymer feed to the glass transition temperature (Tg) before the main heating to melting point. This preliminary heating step increases polymer mobility and reduces viscosity in advance, allowing the subsequent melting process to occur faster without causing thermal degradation. The preheating prepares the polymer chains for rapid processing by reducing their entanglement and increasing their freedom of movement before the high-temperature melting phase.
Solution Approach 2:
The patent utilizes parameter changes by heating the polymer feed to a specific temperature range (above Tg but below melting point) during the preheating phase. This temperature parameter change transforms the polymer from a rigid glassy state to a more mobile rubbery state, fundamentally altering its rheological properties. This parameter transformation enables faster subsequent processing while avoiding the harmful effects of excessive heating.
3Device complexity
If the polymer is heated to melting point in a single step, then the processing is simpler, but the processing speed is limited by reptation time
Solution Approach 1:
The patent applies segmentation by dividing the heating process into two distinct stages: (1) preheating to glass transition temperature (Tg) to increase polymer mobility, and (2) subsequent heating to melting point for processing. This segmentation allows each stage to be optimized independently—the first stage prepares the polymer chains for rapid movement, while the second stage completes the melting process. The result is a significant reduction in overall processing time compared to single-step heating, as the reptation time is reduced in the first stage.
Solution Approach 2:
The patent applies preliminary action by preheating the polymer feed to the glass transition temperature (Tg) before the main heating to melting point. This preliminary heating step increases polymer mobility and reduces viscosity in advance, allowing the subsequent melting process to occur faster without causing thermal degradation. The preheating prepares the polymer chains for rapid processing by reducing their entanglement and increasing their freedom of movement before the high-temperature melting phase.
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 significantly increases the processing speed of 3D printing by up to five- to six-fold, reducing the time required to melt the polymer and improving the mechanical properties of printed objects.
Implementation Method 1
preheating the polymer feed to a temperature above its glass transition temperature but below its melting point
Implementation Method 2
thermal degradation occurs if a polymer is heated too quickly
Implementation Method 3
subsequently raised to its melting temperature (either immediately before or after deposition per the specific process)
Data Source
AI summary
A polymeric material used for 3D printing is preheated, at a first zone in a 3D printer, to a temperature in excess of its glass transition temperature prior to being melted, at a second zone, for incorporation into a build object. This enables the polymer to be processed more rapidly than in the prior art.