3D Printing Filament with Acrylic Polymer Additive for Interlayer Adhesion
Solution Overview
Problem
Current 3D printing technologies face issues with low interlayer adhesion due to negligible shear during the process, leading to structural failures, shrinkage, and warpage in 3D printed objects.
Innovation Solution
A 3D printing filament comprising a thermoplastic resin and an acrylic polymer additive, where the acrylic polymer is present in amounts ranging from 0.1 to 20 parts per hundred of the thermoplastic resin, enhancing interlayer adhesion and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polymer fusion is driven by temperature and shear during melt processing, then interlayer adhesion is improved, but in 3D printing shear is negligible leading to poor adhesion
Solution Approach 1:
The patent changes the chemical composition parameter of the filament by incorporating acrylic polymer additives (0.1-20 phr) into the thermoplastic resin. This chemical modification enables the material to achieve adequate interlayer adhesion at lower shear rates typical of 3D printing, resolving the contradiction between needing shear-driven fusion and the negligible shear available in 3D printing operations.
Solution Approach 2:
The patent creates a composite filament material combining thermoplastic resin with acrylic polymer additives. This composite formulation provides enhanced interlayer adhesion properties that compensate for the lack of shear during 3D printing, allowing the material to bond layers effectively without relying on high shear forces.
2Strength
If higher shear is applied to improve polymer fusion, then interlayer adhesion is enhanced, but 3D printing process cannot provide sufficient shear
Solution Approach 1:
The patent modifies the material composition parameter by adding acrylic polymer additives to the thermoplastic resin. This change allows the material to achieve adequate fusion and adhesion at the lower shear rates and temperatures typical of 3D printing processes, enabling maintained printing speeds without sacrificing interlayer bond strength.
3Ease of manufacture
If material does not adhere properly between layers, then printing process is simple, but structural failure and warpage occur
Solution Approach 1:
The patent develops a composite filament consisting of thermoplastic resin combined with acrylic polymer additives (0.1-20 phr). This composite material formulation enhances interlayer adhesion and reduces warpage while maintaining the simplicity of the 3D printing process, resolving the contradiction between ease of manufacture and structural reliability.
Solution Approach 2:
The patent changes the chemical composition parameter of the filament material to include acrylic polymer additives. This modification improves interlayer bonding and reduces warpage tendencies while requiring no changes to the printing process parameters or procedure, thus maintaining ease of manufacture while improving reliability.
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 filament exhibits improved interlayer adhesion, strength, and reduced shrinkage and warpage, as demonstrated by the ability to withstand higher loads without layer separation during testing.
Implementation Method 1
Interlayer adhesion is driven by polymer fusion
Implementation Method 2
The filament exhibits improved interlayer adhesion
Data Source
AI summary
A filament for three-dimensional printing comprises a thermoplastic resin and an acrylic polymer additive in an amount ranging from 0.1 to 20 parts per hundred of the thermoplastic resin (phr). A 3D printed article prepared from the filament and a process for preparing filament for three-dimensional printing are also disclosed.