Annealed Thermoplastic Elastomer Powders for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing powders, particularly thermoplastic elastomers, face challenges with low flowability, affecting the efficiency of layer formation and bonding in the additive manufacturing process, which is crucial for producing high-performance athletic equipment and footwear.
Innovation Solution
Annealing the additive manufacturing powder by increasing its temperature above the glass transition temperature but below the melting temperature, followed by cooling, enhances its flowability and bonding properties, allowing for improved layer formation and structural integrity in articles like footwear and sporting equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermoplastic elastomer powder is used for additive manufacturing, then elastomeric properties are achieved, but flowability is poor
Solution Approach 1:
The patent applies parameter changes by heating the thermoplastic elastomer powder to a temperature above its glass transition temperature (Tg) but below its melting temperature. This thermal parameter change modifies the powder's physical state, improving flowability while preserving bonding capability. The temperature range is specifically controlled to achieve optimal flow characteristics without compromising the material's ability to bond during additive manufacturing.
Solution Approach 2:
The patent implements preliminary action by pre-heating the powder before the additive manufacturing process. This preliminary thermal treatment prepares the powder with improved flow characteristics in advance, ensuring that when the powder is subsequently used in printing, it exhibits enhanced flowability and layer formation while maintaining its bonding properties during the manufacturing process.
2Ease of operation
If glass transition temperature is exceeded to improve flowability, then powder flowability improves, but melting temperature must be avoided
Solution Approach 1:
The patent precisely controls the temperature parameter within a specific range: above the glass transition temperature (Tg) to improve flowability, but below the melting temperature to prevent material degradation. This controlled parameter change enables the powder to achieve optimal flow characteristics while maintaining structural integrity and bonding capability throughout the additive manufacturing process.
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 annealed powder exhibits improved flowability and bonding, enabling the production of high-performance articles with enhanced durability and performance characteristics, such as improved cushioning and traction in athletic footwear.
Implementation Method 1
increasing the temperature of the additive manufacturing powder to a temperature above the glass transition temperature of the additive manufacturing powder but below a melting temperature of the additive manufacturing powder
Implementation Method 2
cooling the powder to form the annealed additive manufacturing powder
Data Source
AI summary
The present disclosure provides for making annealed additive manufacturing powder, where the powder can be used to make structures using additive manufacturing processes. The additive manufacturing powder can be annealed to improve the flowability of the powder. Once annealed, the powder can be used in the additive manufacturing process and structures can be formed by affixing the powder particles to one another (e.g., by reflowing and re-solidifying a material present in the powder particles). The annealed additive manufacturing powder can be formed in a layer-by-layer additive process to produce articles such as a component of an article of sporting equipment, apparel or footwear, including a sole structure for footwear.