3D Printing Binder Fluid Phosphate Polymer Adhesion
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Solution Overview
Problem
3D printing intermediate parts are fragile due to air voids, making them difficult to handle and transfer from the build platform to a separate heating device for sintering.
Innovation Solution
A binder fluid comprising polymer particles with a phosphate functional group is used to enhance adhesion between metal particles and polymer particles, increasing the tensile strength of the 3D intermediate part and improving its robustness and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional binder fluids are used to form 3D intermediate parts, then the parts can be formed with metal particles, but the intermediate parts become fragile due to air voids and have low tensile strength
Solution Approach 1:
The patent changes the chemical composition parameters of the binder fluid by incorporating polymer particles with specific functional groups (carboxyl, hydroxyl, or amine groups) that can chemically interact with metal particle surfaces. This chemical parameter change enhances adhesion strength and eliminates air voids, directly improving tensile strength and robustness of the 3D intermediate parts.
Solution Approach 2:
The patent creates a composite binder system combining polymer particles with specific functional groups that work synergistically with metal particles. The functional groups form chemical bonds with metal surfaces while the polymer matrix provides structural continuity, creating a composite material that eliminates air voids and significantly enhances both tensile strength and robustness.
2Ease of operation
If the 3D intermediate part is made robust enough for handling, then it can be transferred safely, but the binder fluid composition becomes more complex
Solution Approach 1:
The patent modifies the binder fluid by adding polymer particles with specific functional groups (carboxyl, hydroxyl, or amine) in controlled amounts (0.1-10 wt%). This parameter change enhances chemical adhesion to metal particles, creating robust intermediate parts that are easy to handle and transfer, while maintaining a relatively simple formulation approach.
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 use of polymer particles with a phosphate functional group significantly enhances the tensile strength of the 3D intermediate part, allowing it to withstand extraction from the build platform and handling during transfer to the heating device.
Implementation Method 1
A binder fluid comprising polymer particles with a phosphate functional group is used to enhance adhesion between metal particles and polymer particles, increasing the tensile strength of the 3D intermediate part
Data Source
AI summary
An example of a three-dimensional printing kit includes a particulate build material including from about 80 wt % to 100 wt % metal particles based on a total weight of the particulate build material. The three-dimensional printing kit further includes a binder fluid including water and polymer particles in an amount ranging from about 1 wt % to about 40 wt % based on a total weight of the binder fluid. The polymer particles have from about 1% to about 10% of a phosphate functional group.