3D Printed Surface Zoning for Coating-Adherent 2D Patterns
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Solution Overview
Problem
Existing 3D printable materials with chemically inert and nonporous surfaces have low surface tensions, making them non-receptive to bonding with printing inks and adhesives, hindering the efficient application of 2D patterns on 3D printed objects.
Innovation Solution
A method involving core-shell type printing is employed, where a first thermoplastic polymer forms the core and a second thermoplastic polymer with different polarity and/or porosity forms the shell, enhancing the affinity of the surface for coatings, allowing for improved adhesion of inks or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chemically inert and nonporous 3D printable materials are used, then manufacturing simplicity and structural integrity are improved, but surface receptiveness to bonding with printing inks and adhesives deteriorates
Solution Approach 1:
The invention applies local quality by creating a core-shell structure where the core maintains the chemically inert and nonporous properties of standard 3D printable materials for structural integrity, while the shell layer has modified surface properties (increased polarity and porosity) to enhance bonding receptiveness. This allows different regions of the same object to have different material properties optimized for their specific functions.
Solution Approach 2:
The invention uses composite materials by combining a first thermoplastic polymer (core) with a second thermoplastic polymer having different polarity and/or porosity (shell). This composite core-shell structure integrates the manufacturing simplicity of conventional materials with the bonding enhancement provided by the second material's superior surface properties.
2Device complexity
If a single uniform material is used for 3D printing, then manufacturing complexity is reduced, but the ability to create surfaces with enhanced coating adherence deteriorates
Solution Approach 1:
The invention segments the 3D printed object into distinct functional zones: a core region for structural support and a shell region for enhanced coating adherence. This segmentation is achieved through core-shell type printing where the first material forms the core and the second material forms the shell, allowing each zone to be optimized independently.
Solution Approach 2:
The invention applies parameter changes by varying key material parameters (polarity and porosity) between the core and shell layers. The second thermoplastic polymer is specifically selected to have different polarity and/or porosity compared to the first material, enabling the shell to provide enhanced coating adherence while the core maintains structural integrity.
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 efficient transfer of 2D patterns onto 3D printed objects by creating a surface with enhanced coating adherence, ensuring correct pattern positioning and visual differentiation.
Implementation Method 1
many plastic materials used as 3D printable materials for FDM have chemically inert and nonporous surfaces with low surface tensions causing them to be non-receptive to bonding with printing inks, coatings, and adhesives
Implementation Method 2
a second thermoplastic polymer with different polarity and/or porosity forms the shell
Implementation Method 3
FDM works on an 'additive' principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part
Data Source
Figure 1a~1b
AI summary
The present invention relates to a method for producing a 3D item (1) by means of fused deposition modelling, the method comprising the step of: a) layer-wise depositing a first 3D printable material (4) and a second 3D printable material (5) to provide the 3D item (1) comprising a layer stack (2) having an exposed surface (3), wherein the first 3D printable material (4) has a first polarity and a first porosity; wherein the second 3D printable material (5) has a second polarity and a second porosity; the first polarity being different from the second polarity and/or the first porosity being different from the second porosity; wherein the first 3D printable material (4) forms a first surface portion (4´) of the exposed surface (3) of the layer stack (2), and the second 3D printable material (5) forms a second surface portion (5´) of the exposed surface (3) of the layer stack (2); wherein the method further comprises the step of: b) applying a coating (7) on the second surface portion (5´) of the exposed surface (3) of the layer stack (2).