Additive Manufactured Object Infusion with Thermoplastic Polymer
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Solution Overview
Problem
Current methods for strengthening and protecting three-dimensional printed, free-form fabricated, or additive manufactured objects, such as impregnation with acrylic resin, waxes, or curable resins, face issues like toxicity, shrinkage, unsatisfactory finishes, and limited structural integrity, as well as the inability to reverse unsatisfactory results.
Innovation Solution
Infusing these objects with a thermoplastic polymer that sets at a lower temperature than its melting point, allowing deep penetration into pores and voids under controlled temperature and pressure conditions, using a multi-functional apparatus for pre-treatment, immersion, drainage, and curing, and employing polycaprolactones for enhanced structural integrity and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If acrylic resin (cyanoacrylate) is used for impregnation, then bonding strength is improved, but toxicity and premature spoilage worsen
Solution Approach 1:
The invention changes the chemical composition parameters of the impregnating material from cyanoacrylate-based acrylic resin to a two-part component resin system (epoxy, polyester, or polyacrylate). This parameter change eliminates the toxicity and premature spoilage issues while maintaining bonding strength through the two-part mixing mechanism that prevents premature setting.
Solution Approach 2:
The invention introduces a two-part component system where separate components (resin and hardener) act as intermediaries that only become reactive when mixed. This intermediary approach allows the materials to be stored separately without spoilage, eliminating the harmful effects of premature polymerization while maintaining the bonding function when properly mixed and applied.
2Object-affected harmful factors
If waxes are used for impregnation, then safety is improved, but shrinkage and finish quality worsen
Solution Approach 1:
The invention changes the physical parameters of the impregnating material from wax (solid at room temperature, hydrophobic) to a two-part component resin system that remains liquid/workable until mixed and applied. This parameter change eliminates shrinkage and finish quality issues while maintaining safety through the use of non-toxic, non-flammable resin systems.
3Stability of the object's composition
If curable resin is used for impregnation, then permanent finish is improved, but reworkability and structural integrity worsen
Solution Approach 1:
The invention changes the curing mechanism parameters from UV or heat curing (which create permanent, non-reversible finishes) to a two-part component chemical curing system. This parameter change provides permanent finish through chemical bonding while maintaining reworkability by allowing the uncured mixed resin to be removed or reworked before final setting, and enabling selective areas to be re-treated.
4Ease of repair
If two-part component resin is used for impregnation, then reworkability is improved, but mixing wastage and finish quality worsen
Solution Approach 1:
The invention applies partial action by allowing the two-part components to be mixed and applied selectively rather than requiring complete saturation. The resin can be applied to specific areas needing reinforcement, and any excess or improperly mixed material can be removed before setting, reducing wastage while maintaining reworkability.
5Manufacturing precision
If impregnation material is applied, then surface finish is improved, but deep penetration and structural integrity worsen
Solution Approach 1:
The invention ensures continuous useful action by maintaining the resin in a liquid/workable state throughout the impregnation process. The two-part component system allows the resin to penetrate deeply into pores and voids while remaining fluid, then continues to cure uniformly throughout the entire structure, ensuring both surface finish quality and deep structural penetration simultaneously.
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 provides stronger, better-finished objects with reduced shrinkage and the ability to reverse unsatisfactory infusions, while ensuring safety and preventing premature spoilage, offering improved structural integrity and quality finishes.
Implementation Method 1
They can be caused to impregnate the pores and voids deeply (and not just the outer surface), resulting in less shrinkage and greater structural integrity
Implementation Method 2
a thermoplastic polymer which will impregnate the pores and voids in a molten state in a first defined temperature range and set at a second temperature range (lower than said first)
Implementation Method 3
the thermoplastic material which is a linear or branched semi-crystalline aliphatic polyester with a melting point of between 40°C and 65°C which has a solidification/crystalisation point between 20°C and 40°C
Data Source
AI summary
A method of infusing, infiltrating or impregnating a three dimensional printed, free-form fabricated or additive manufactured object having pores or voids in or between particles or sheets of material from which the object is manufactured may include infusing the object with a thermoplastic material. The thermoplastic material may be a linear or branched semi-crystalline aliphatic polyester with a melting point of between 40° C. and 65° C. which may have a solidification/crystalisation point between 20° C. and 40° C., and which may be introduced under controlled conditions of temperature and pressure. The thermoplastic material may be caused to penetrate the object by immersing the object in the thermoplastic material and controlling the frequency and amplitude of pressure oscillation to ensure sufficient infusion into the object to penetrate the pores or voids by at least 10% and bond particles or sheets of material from which the object is manufactured.