Adhesive Coating for Additive Manufacturing Surface Smoothing
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Solution Overview
Problem
Objects produced by additive manufacturing have rough surfaces, leading to adhesion issues with existing coatings, paint failures due to expansion and contraction, and lack of durability, especially when subjected to mechanical forces and thermal cycling.
Innovation Solution
A composition comprising core shell vinyl ester resin and urethane acrylate, with optional additives, applied as an adhesive coating to create a smooth surface that adheres well to common substrates, withstands mechanical forces, and remains impervious to gas and liquid, even under thermal cycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grinding is used to smooth the surface, then surface smoothness is improved, but time consumption and dust generation increase significantly
Solution Approach 1:
The adhesive coating is applied to the additive manufactured object before final use, creating a smooth surface layer in advance. This preliminary action eliminates the need for subsequent grinding operations, saving time and avoiding dust generation while achieving the required surface smoothness for painting and finishing.
2Ease of manufacture
If existing coating compositions are used, then application is simplified, but adhesion to common substrates like ABS and PPS is insufficient
Solution Approach 1:
The invention uses a composite adhesive composition containing both epoxy resin and polyurethane resin components. This composite material combines the strong adhesion properties of epoxy with the flexibility and chemical resistance of polyurethane, enabling reliable bonding to diverse substrates like ABS and PPS while maintaining ease of application through a two-part mixing system.
3Manufacturing precision
If traditional paint is applied to additive manufactured objects, then surface appearance is improved, but paint failure occurs due to expansion and contraction
Solution Approach 1:
The adhesive composition is formulated with specific resin ratios and cross-linking densities that allow it to accommodate the thermal expansion and contraction of additive manufactured substrates. The polyurethane component provides flexibility while the epoxy provides strength, creating a coating system that maintains adhesion and surface appearance through temperature cycles without cracking or peeling.
4Area of stationary object
If existing coating compositions are used on large objects, then application coverage is improved, but pooling and cracking occur
Solution Approach 1:
The adhesive composition exhibits dynamic rheological properties that allow it to flow and self-level when applied to large surfaces, then set into a stable, uniform structure. The combination of epoxy and polyurethane resins creates a system with appropriate viscosity and curing characteristics that prevents pooling during application while ensuring even coverage and crack-free drying across large areas.
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 composition achieves a bond strength greater than 300 psi, maintains surface smoothness, and withstands multiple pulls and thermal changes, enhancing the durability and usability of objects produced by additive manufacturing for applications like molds and prototypes.
Implementation Method 1
an adhesive coating comprising core shell vinyl ester resin or the present composition of core shell vinyl ester resin and urethane acrylate
Implementation Method 2
fills voids of objects having a rough or uneven surface present on certain substrates
Implementation Method 3
the adhesive coating, after it has been cured, may have a finished surface profile of less than 0.10 mm
Implementation Method 4
paint failures are common due to inability of paint to withstand the expansion and contraction of the object
Data Source
AI summary
An adhesive composition comprising a core shell vinyl ester and a urethane acrylate, which is suitable to be applied to a rough or uneven surface of a substrate to render a smooth surface. The present adhesive composition is particularly suitable to coat large objects made through additive manufacturing to form molds or prototypes.