Amorphous Polymer 3D Printing Selectivity via Coalescent Fluids
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Solution Overview
Problem
Amorphous polymers pose challenges in 3D printing due to their lack of a specific melting point, leading to poor selectivity and caking issues, as they soften gradually over a range of temperatures, making it difficult to form fused portions without fusing neighboring particles.
Innovation Solution
The use of coalescent fluids containing viscosity reducing agents that lower the viscosity of amorphous polymer powders, allowing for selective fusion at lower temperatures while keeping surrounding particles unfused, by combining with thermal fusing agents to absorb energy from electromagnetic radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electromagnetic radiation is applied to fuse amorphous polymer powder, then fusion occurs, but selectivity between fused and unfused portions deteriorates due to gradual softening over temperature range
Solution Approach 1:
The patent changes the physical-chemical parameters of the polymer powder by incorporating particles with different thermal properties (metal particles, ceramic particles, or polymer particles with different glass transition temperatures). This allows the composite powder to have a more defined fusion temperature range, improving selectivity during electromagnetic radiation exposure while maintaining controllable temperature behavior.
Solution Approach 2:
The patent creates composite polymer powder by combining amorphous polymer particles with secondary particles (metal, ceramic, or different polymer types). This composite structure enables differential response to electromagnetic radiation, where the secondary particles affect the thermal and optical properties to achieve better fusion selectivity and reduce unwanted softening of surrounding particles.
2Productivity
If thermal fusing agents are used to absorb electromagnetic radiation energy, then fusion efficiency improves, but energy consumption increases
Solution Approach 1:
The patent applies thermal fusing agents selectively only to the regions where fusion is desired, rather than uniformly throughout the entire powder bed. This localized application ensures that electromagnetic radiation energy is absorbed primarily where needed, improving fusion efficiency while minimizing overall energy consumption by avoiding unnecessary heating of surrounding areas.
3Manufacturing precision
If printing temperature is increased to ensure complete fusion, then fusion quality improves, but caking of surrounding particles increases
Solution Approach 1:
The patent modifies the thermal parameters of the polymer powder through composite formulation, creating materials that maintain structural integrity at higher temperatures while achieving complete fusion at the printed locations. The secondary particles (metal, ceramic, or high-Tg polymer) provide thermal stability that prevents surrounding particles from caking even when printing temperature is increased to ensure complete fusion quality.
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 improves the selectivity between fused and unfused portions, reducing caking and enhancing the quality of 3D printed parts by allowing precise control over the fusion process, even with amorphous polymers that lack a characteristic melting point.
Implementation Method 1
A thermal fusing agent can be combined with the viscosity reducing agent. The thermal fusing agent can absorb energy from an electromagnetic radiation fusing source, such as a fusing lamp, to a temperature sufficient to fuse the printed portion of the amorphous polymer powder.
Implementation Method 2
The thermal coalescent fluid can absorb more energy from the fusing source, e.g., typically the entire bed. Absorbed fusing light energy can be converted to thermal energy, causing the printed portions of the powder to melt and coalesce.
Implementation Method 3
The coalescent fluid can include a viscosity reducing agent that lowers the viscosity of the amorphous polymer powder. The viscosity reducing agent can enable fusion of the amorphous polymer powder at a reduced temperature.
Implementation Method 4
The bed can be exposed to an electromagnetic radiation fusing source, e.g., typically the entire bed. Absorbed fusing light energy can be converted to thermal energy, causing the printed portions of the powder to melt and coalesce.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
The present disclosure is drawn material sets, coalescent fluids, and 3-dimensional printing systems. An example material set can include an amorphous polymer powder having an average particle size from 1 micron to 300 microns, and a coalescent fluid including a viscosity reducing agent.