3D Printing Composition with Thermoplastic Particles
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Solution Overview
Problem
Traditional 3D printing materials often compromise between mechanical properties and surface finish, with thermoset materials offering good surface finish but poor mechanical properties, and thermoplastic materials like ABS providing reasonable mechanical properties but poor surface finish due to heat-assisted extrusion or sintering processes.
Innovation Solution
A composition comprising a rigid liquid curable monomer, an elastic solid thermoplastic particle, and a light-sensitive additive, which forms an intertwined polymeric network upon exposure to light, achieving both desirable mechanical properties and surface finish, similar to thermoset and thermoplastic materials respectively, through light curing/fusing rather than heat-assisted methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermoset materials are used for 3D printing, then surface finish is improved, but mechanical properties deteriorate
Solution Approach 1:
The patent uses a composite material system combining thermoplastic polymer particles (providing mechanical strength and elasticity) with a photopolymerizable matrix (providing surface finish and rigidity). This composite approach allows the final 3D printed object to simultaneously achieve the smooth surface finish characteristic of thermoset materials and the mechanical properties characteristic of thermoplastic materials, resolving the contradiction between surface finish and mechanical strength.
2Strength
If thermoplastic materials like ABS are used for 3D printing, then mechanical properties are improved, but surface finish deteriorates
Solution Approach 1:
The invention creates a composite where thermoplastic polymer particles are embedded in a photopolymerizable matrix. The thermoplastic particles provide the mechanical strength and elongation properties, while the photopolymerizable matrix cures to a smooth finish upon light exposure, thus achieving both good mechanical properties and surface finish simultaneously.
Solution Approach 2:
The patent replaces the traditional heat-based curing mechanism with a light-based photopolymerization mechanism. This substitution allows the material to cure without the thermal effects that cause surface roughness in traditional thermoplastic 3D printing, thereby achieving smooth surface finish while maintaining mechanical integrity.
3Manufacturing precision
If light curing is used instead of heat-assisted extrusion, then surface finish is improved, but production time increases
Solution Approach 1:
The patent employs a continuous photopolymerization process where light exposure continuously cures the photopolymerizable matrix as layers are deposited. This continuous action eliminates the need for separate heating and cooling cycles, maintaining smooth surface finish while reducing overall production time compared to traditional heat-assisted methods.
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 composition enables the rapid fabrication of 3D objects with mechanical properties comparable to traditional ABS resins, such as tensile modulus greater than 2 GPa, tensile strength up to 45 MPa, and elongation at break of up to 14%, while maintaining a surface finish with RMS roughness less than 5 μm, significantly improving production time compared to traditional materials.
Implementation Method 1
a light sensitive additive, which forms an intertwined polymeric network upon exposure to light
Data Source
AI summary
A composition for three-dimensional printing includes a liquid, curable, cross-linkable monomer, solid thermoplastic particles mixed with the liquid, curable, cross-linkable monomer, and a light sensitive initiator mixed with the liquid, curable, cross-linkable monomer. The solid thermoplastic particles have a size ranging from about 200 nm to about 50 μm.