3D Printed Alumina Abrasive Particles via Optical Curing
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Solution Overview
Problem
Existing methods for producing ceramic abrasive particles are laborious for creating complex shapes, particularly in filling gel into molds and releasing them after firing, and struggle with efficient packing and alignment on substrates.
Innovation Solution
The method employs 3D printing technology using an optically binding binder that cures under electromagnetic radiation, allowing for layer-by-layer formation and local curing of abrasive particles with specific shapes, such as six plane-parallel volume bodies with triangular walls and ridge faces, enabling dense packing and self-orientation on substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If gel is filled into molds and released after firing, then abrasive particles with specific shapes can be produced, but the process becomes laborious and complex
Solution Approach 1:
The patent replaces the mechanical molding process (filling gel into molds and releasing after firing) with a light-based curing process. An optically active binder is used that cures under electromagnetic radiation, allowing the gel to be shaped and fixed without mechanical molds. This substitution eliminates the laborious mold filling and release steps while maintaining shape control through optical means.
Solution Approach 2:
The patent changes the state of the binder from uncured to cured by applying electromagnetic radiation. This parameter change (chemical state transformation) allows the gel material to be fixed in specific shapes without requiring mechanical constraints. The binder transitions from a fluid state that can be shaped to a solid state that maintains the desired geometry, eliminating the need for complex mold operations.
2Shape
If complex shapes of abrasive particles are produced using traditional molding, then specific abrasive properties can be achieved, but the manufacturing becomes laborious
Solution Approach 1:
The patent replaces time-consuming mechanical molding operations with rapid optical curing. Instead of manually or mechanically filling complex mold cavities and then releasing the fired parts, the system uses electromagnetic radiation to quickly cure the binder in the desired complex shapes, dramatically reducing manufacturing time while achieving the same geometric complexity.
Solution Approach 2:
The patent applies the optically active binder to the gel material before shaping is required. This preliminary action ensures that when the gel is shaped into complex forms, the binder is already in position to cure and fix the geometry, eliminating the need for subsequent mold filling and release operations that would consume additional time.
3Quantity of substance
If abrasive particles are produced with enhanced packing density, then substrate coverage is improved, but alignment and positioning become more challenging
Solution Approach 1:
The patent employs abrasive particles with self-oriented shapes that automatically align in specific orientations when applied to substrates. The asymmetric geometry and surface features of the particles cause them to self-align during the application process, eliminating the need for manual or mechanical alignment operations. This self-service mechanism allows high packing density to be achieved without compromising ease of operation, as the particles naturally position themselves optimally.
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 the efficient production of complex abrasive particle shapes with enhanced abrasive performance, stability against lateral loads, and dense packing, reducing the need for laborious alignment and post-drying processes.
Implementation Method 1
adding an optically binding binder to the sol or gel, successively and layer by layer applying the gel material and curing it by means of an optical binder which cures under electromagnetic radiation of a specific frequency
Implementation Method 2
In the course of the subsequent thermal treatment, i.e. the calcination or sintering of the gel material of the shaped bodies in a manner known as such, the binder evaporates or oxidizes
Data Source
AI summary
The invention relates to a method for producing an alumina based abrasive particle (1), comprising at least the following steps:forming a sol as a solution or dispersion of alumina particles,gelling the sol by adding gelling agents,forming shaped bodies from the gel using an additive procedure,drying and firing the shaped bodies while retaining the previously achieved geometry of the abrasive particles.Hereby, it is provided thatan optically binding binder is added to the sol and/or the gel,the gel is applied additively layer by layer and the binder is set using electromagnetic radiation so as to form the shaped bodies.The produced abrasive particle may be formed, in particular, by six intersecting or overlapping triangular volume regions.