Additive Manufacturing Linear Polymer Reactive Liquid
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Solution Overview
Problem
Current additive manufacturing techniques, such as binder jetting, require energy-intensive processes like UV curing and lasers, leading to high equipment costs and porosity in printed objects, limiting their efficiency and scalability for mass production.
Innovation Solution
A method involving particle-based reactive 3D printing, where a reactive liquid with bi-functional units is deposited onto particulate polymeric material to form extended linear polymer chains without the need for UV light or heat, reducing porosity and energy requirements, and allowing for faster and more cost-effective production of thermoplastic objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binder jetting with UV curing is used, then objects can be formed with cross-linked polymers, but energy consumption increases and equipment cost rises
Solution Approach 1:
The invention changes the chemical parameter of the polymer structure from cross-linked to linear chains. By using linear polymeric particles with reactive end groups that react with bifunctional monomers, the process eliminates the need for UV curing while maintaining structural integrity through linear polymer extension rather than cross-linking
Solution Approach 2:
The invention extracts and eliminates the UV curing step from the binder jetting process. By using chemically reactive linear polymers that can be cured by alternative methods or that form stable linear structures, the patent removes the energy-intensive UV light source while still achieving polymerization and object formation
2Strength
If binder jetting with UV curing is used, then objects can be formed with cross-linked polymers, but equipment cost increases
Solution Approach 1:
The invention extracts and eliminates the UV curing apparatus from the binder jetting system. By using linear polymeric particles with reactive end groups that can be polymerized through alternative lower-cost methods or that form stable linear structures, the patent removes expensive UV light sources and associated equipment while maintaining object formation capability
Solution Approach 2:
The invention changes the polymer chemistry parameter from cross-linked to linear structures. This fundamental chemical parameter change allows the use of simpler, lower-cost equipment while still achieving adequate mechanical properties through linear polymer extension and potential alternative curing mechanisms
3Productivity
If conventional binder jetting is used, then objects can be formed, but porosity increases reducing object density
Solution Approach 1:
The invention changes the polymer structure parameter from cross-linked to linear chains with reactive end groups. This allows for better particle fusion and reduced porosity as the linear chains can extend and interconnect more effectively, filling voids between particles and creating denser, more homogeneous objects
4Ease of manufacture
If high energy processes like laser or electron beam are used, then materials can be processed, but energy consumption and processing time increase
Solution Approach 1:
The invention extracts and eliminates high-energy processing steps like laser or electron beam irradiation. By using linear polymeric particles with reactive end groups that can undergo lower-energy polymerization reactions or that form stable structures through chemical reaction alone, the patent removes time-consuming high-energy processing while maintaining material processing capability
Solution Approach 2:
The invention enables the polymeric particles to self-assemble and self-bond through their inherent chemical reactivity. The reactive end groups on linear polymer chains automatically react with bifunctional monomers without requiring external high-energy input, allowing the material to process itself at lower energy levels and faster speeds
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 method enables the rapid and efficient production of solid, thermoplastic objects with reduced porosity and lower energy consumption, enhancing printing speed and economic viability for mass production while maintaining the thermoplastic properties of the starting material.
Implementation Method 1
allowing linear polymeric chains in said layer of polymeric material to react with reactive units in said reactive liquid so as to form extended polymeric chains that are linear
Data Source
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AI summary
A method (300) of fabricating an object by additive manufacturing comprises providing (310) a layer of polymeric material (100), said polymeric material (100) being in particulate form, and comprising linear polymer chains, selectively depositing (320) a reactive liquid (200) onto the layer of particulate polymeric material (100), said reactive liquid (200) comprising reactive units (210a) which are monomeric units, linear oligomeric units, linear polymeric units, or combinations thereof, wherein said reactive units (210a) have two or fewer reactive groups, and allowing (330) linear polymeric chains in said layer of polymeric material (100) to react with reactive units in said reactive liquid (200) so as to form extended polymeric chains that are linear, so as to provide a shaped layer of linear polymer. These steps (310, 320, 330) are repeated as required to form the object from successive shaped layers of linear polymer.