Water-based binder solutions for use in additive manufacturing processes
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Solution Overview
Problem
Conventional binder solutions for additive manufacturing require a long wick time, reducing throughput and increasing the time needed for layer deposition, while solutions with improved wicking times often adversely impact surface roughness.
Innovation Solution
Aqueous binder solutions comprising a thermoplastic binder with specific molecular weight ranges and non-aqueous solvents with boiling points above 100°C, which facilitate rapid wicking and balanced cure times without affecting surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional binder solutions are used, then surface roughness is maintained, but wick time is too long reducing throughput
Solution Approach 1:
The patent changes the chemical composition parameters of the binder solution by incorporating specific non-aqueous solvents (ethylene glycol, propylene glycol, butanol) with controlled concentrations (1-10 wt%) alongside water and binder polymers. This parameter modification enables the solution to achieve optimal wick time (2-10 seconds) while maintaining acceptable surface roughness, thereby resolving the contradiction between throughput and wick time.
Solution Approach 2:
The binder solution functions as a composite material system combining multiple components: water (primary solvent), non-aqueous solvents (ethylene glycol, propylene glycol, butanol in specific ratios), binder polymers (PVA, PVP, carboxymethyl cellulose), and optional surfactants. This composite formulation synergistically balances wicking performance and surface quality, enabling both improved throughput and maintained surface roughness characteristics.
2Productivity
If binder solutions with improved wicking time are used, then throughput increases, but surface roughness is adversely impacted
Solution Approach 1:
The patent precisely controls the concentration parameters of non-aqueous solvents (1-10 wt% range) and binder polymers (5-20 wt% range) to achieve optimal balance. By adjusting these parameters, the formulation attains wick time of 2-10 seconds (improved throughput) while maintaining surface roughness within acceptable manufacturing tolerances, thus resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The binder solution exhibits local quality differentiation through its multi-component composition: non-aqueous solvents (ethylene glycol, propylene glycol, butanol) provide controlled wicking speed in the bulk material, while binder polymers (PVA, PVP, carboxymethyl cellulose) ensure surface adhesion and finish quality. This spatial-functional differentiation resolves the contradiction between improved wicking (throughput) and surface quality (manufacturing precision).
3Productivity
If wick time is reduced for faster layer deposition, then productivity improves, but cure time is shortened impacting quality
Solution Approach 1:
The patent modifies the evaporative properties of the binder solution by incorporating non-aqueous solvents (ethylene glycol, propylene glycol, butanol) with higher boiling points than water. This parameter change enables the solution to maintain extended cure time despite reduced wick time (2-10 seconds), allowing faster layer deposition while preserving quality through prolonged curing duration.
Solution Approach 2:
The binder solution maintains continuous useful action through its multi-solvent system: water provides initial wetting and wicking, while non-aqueous solvents (ethylene glycol, propylene glycol, butanol) ensure sustained evaporation and curing over an extended period. This continuity enables both rapid layer deposition (improved productivity) and adequate cure time (maintained quality) to coexist.
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 solution enables increased throughput and maintains surface smoothness by reducing wick time and evaporation rate, resulting in stronger green body parts suitable for handling during post-printing processes.
Implementation Method 1
Conventional binder solutions may require a relatively long time to wick into the layer of powder
Implementation Method 2
some binder solutions that have achieved improved wicking time also exhibit an evaporation rate that adversely impacts the surface roughness
Data Source
AI summary
In various embodiments, a water-based binder solution for use in additive manufacturing, includes a thermoplastic binder. The thermoplastic binder includes a first polymer strand having a weight average molecular weight (Mw) of from greater than or equal to 5,000 g/mol to less than or equal to 15,000 g/mol, a second polymer strand having a weight average molecular weight of from greater than or equal to 10,000 g/mol to less than or equal to 50,000 g/mol, and a third polymer strand having a weight average molecular weight of from greater than or equal to 1,000 g/mol to less than or equal to 5,000 g/mol. The binder solution further comprises from greater than or equal to 0.1 wt % to less than or equal to 5 wt % of a non-aqueous solvent having a boiling point of greater than 100° C.