3D Shaping Paste Resolving Sintering Distortion

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Solution Overview

Problem

Existing methods for producing three-dimensional shaped articles often result in distortion due to volume changes during sintering, as the support layer does not accommodate shrinkage, leading to inaccurate final products.

Innovation Solution

A three-dimensional shaping paste containing a solvent, a binder, support layer forming particles, and resin particles with a decomposition temperature lower than the sintering temperature, where the resin particles are between 20% to 60% of the total volume, allowing for volume reduction of the support layer during sintering, thus preventing distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a support layer is formed to support the constituent layer during sintering, then the constituent layer can be supported and easily peeled off after sintering, but the support layer cannot accommodate the volume change (shrinkage) of the constituent layer during sintering, causing distortion of the sintered body

Engineering Contradiction:

Improvesupport functionVSAvoidshape accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention changes the material composition parameters of the support layer by incorporating organic particles with decomposition temperatures below the sintering temperature. This allows the support layer to undergo controlled volume reduction during sintering, accommodating the shrinkage of the constituent layer and preventing distortion while maintaining support functionality.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite support layer material combining inorganic particles (providing structural support) with organic particles (providing shrinkage accommodation through decomposition). This composite structure enables the support layer to simultaneously fulfill the support function and adapt to volume changes during sintering, resolving the contradiction between reliability and manufacturing precision.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If the support layer maintains a constant shape to provide stable support, then it can reliably support the constituent layer, but it interferes with the shrinkage of the constituent layer during sintering, leading to deformation

Engineering Contradiction:

Improvesupport layer stabilityVSAvoiddimensional accuracy

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The invention introduces dynamic behavior to the support layer by incorporating organic particles that decompose at controlled temperatures. The support layer transitions from a rigid, constant-shape structure to a dynamic structure that can adapt its volume during sintering, allowing it to maintain stability during support while accommodating dimensional changes to prevent deformation.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If traditional support layer materials are used that do not undergo melting or sintering, then they can be easily peeled off after sintering, but they cannot reduce their volume to accommodate the shrinkage of the constituent layer, causing distortion

Engineering Contradiction:

Improvepeeling easeVSAvoidshape accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention extracts the harmful constraint of constant volume from the support layer by introducing organic particles that decompose and volatilize during sintering. This removal of volume constraint allows the support layer to shrink and accommodate the constituent layer's shrinkage, preventing distortion while the remaining inorganic particles and binder ensure easy peeling after sintering.

Inventive Principle:

Principle #2Taking out (Extraction)

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 highly accurate three-dimensional shaped articles by allowing the support layer to shrink in response to the constituent layer's volume changes, preventing deformation and ensuring precise shape retention.

Implementation Method 1

it is possible to volatilize the material and to cause the support layer forming first particles to move to the region of the volatilized material by subjecting the material to a temperature that is lower than the sintering temperature of the support layer forming first particles and higher than the decomposition temperature of the material

Methodology Applied

Scientific EffectVolatilization: Evaporation

Implementation Method 2

a binder that is soluble in the solvent

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

sintering the constituent layer

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS10730235B2Paste and method for producing three-dimensional shaped article

Publication Date: 2020.08.04 SEIKO EPSON CORP

AI summary

There is provided a paste for use in producing a three-dimensional shaped article, the paste containing a solvent, a binder that is soluble in the solvent, support layer forming first particles, and a material having a decomposition temperature lower than a sintering temperature of the support layer forming first particles, in which the material is contained in a volume of greater than or equal to 20% and less than or equal to 60% with respect to a total volume of the support layer forming first particles and the material being 100%. By using such a paste, a highly accurate three-dimensional shaped article can be produced.