3D Printing Binder Fluids with Fine Particulate Matter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional three-dimensional printing processes face limitations in surface contour resolution, apparent density, and the inability to locally tailor properties of printed articles, resulting in low surface finish and significant material requirements for densification, which can lead to geometrical distortion.
Innovation Solution
The method involves selectively depositing a binder fluid with particulate matter smaller than the build material powder, increasing the density and surface finish of the printed articles by filling interparticle interstices, and using multiple print head systems to apply different binder fluids with varying particulate sizes for localized property modulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional binder fluid jet deposition is used, then the printing process is simple, but the surface contour resolution is poor (on the order of particle layer thickness, 50-500 microns)
Solution Approach 1:
The binder fluid is formulated as a composite material containing both binder and fine particulate matter (1-50 microns). This composite binder fluid allows the jet deposition process to simultaneously achieve binding and surface smoothing, improving contour resolution without requiring separate processing steps.
Solution Approach 2:
The fine particulate matter in the binder fluid selectively fills interparticle interstices and smooths surface irregularities where the binder is deposited. This local action occurs precisely at the printed areas, improving surface quality without affecting the entire powder bed or requiring global process changes.
2Manufacturing precision
If conventional binder fluid jet deposition is used, then the process is straightforward, but the apparent density of the printed part is low (50-60% packing density)
Solution Approach 1:
The binder fluid contains fine particulate matter (1-50 microns) that acts as an infiltrant, filling the voids between larger build material particles. This composite approach increases the apparent density of the printed part directly during the printing process, eliminating the need for separate infiltration steps.
Solution Approach 2:
The fine particulate matter is pre-loaded into the binder fluid before printing. This preliminary preparation allows the densification action to occur simultaneously with the binding process, rather than requiring a subsequent separate infiltration operation after printing is complete.
3Adaptability or versatility
If all areas receive the same binder fluid, then the process is simple, but the ability to locally tailor properties of the article is lost
Solution Approach 1:
Different binder fluids with varying fine particulate matter compositions can be selectively deposited in different regions of the printed part. This allows local tailoring of properties such as density, surface finish, or material composition in specific areas while maintaining the overall printing process framework.
Solution Approach 2:
The printing system can be divided into multiple print heads or zones, each capable of depositing different binder fluid compositions. This segmentation enables simultaneous or sequential application of different binder formulations to different regions, achieving spatially varying material properties.
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 enhances the surface finish and density of three-dimensionally printed articles, allowing for improved contour resolution and the ability to locally tailor properties, reducing material requirements and minimizing geometrical distortion during densification.
Implementation Method 1
selectively jet-printing a fluid onto that layer to cause selected portions of the particulate layer to bind together
Implementation Method 2
The jet-deposited material acts to fill in the interparticle interstices of the build material powder thereby simultaneously increasing the density
Implementation Method 3
improving its surface roughness and contour resolution, which in turn, improves the surface finish of the final article
Implementation Method 4
selectively jet-printing a fluid onto that layer to cause selected portions of the particulate layer to bind together
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Methods and systems (2) are disclosed for making articles (114) by three-dimensional printing. The methods include selectively printing by jet deposition on successive layers (4) of a build material powder (10) at least one of a first binder fluid and a second binder fluid. At least one of the first and second binder fluids includes a particulate matter (16) having mean particle size diameter which is less than that of the build material powder (10). The first binder fluid is characteristically different from the second binder fluid. The particulate matter (16) selectively deposited with a binder fluid can be used to locally tailor the physical properties of the article (114), e.g. by alloying with the build material powder, increasing densification, acting as a local infiltrant or infiltrant stop during heat treatment, locally modulating the local stress fields (e.g. by a mismatch of thermal coefficients of expansion), etc. Among the possible locally tailored properties is the surface finish of an interior or exterior surface of the article (114).