3D Printing Binding Agent for Green Body Structural Integrity
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Solution Overview
Problem
Current 3D printing methods face challenges in achieving sufficient structural integrity of green body objects during the printing process, particularly during transfer and sintering, which can lead to issues with automated part extraction and final object strength.
Innovation Solution
A binding agent comprising multi-functional carboxylic acid, (meth)acrylic latex binder, solvent package, and water is applied to particulate build material layers, providing structural integrity before sintering, with specific weight percentages and molecular weight ranges, and a three-dimensional printing kit using metal particles and this binding agent to form a green body object that is then sintered.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional binding agents are used in 3D printing, then the printing process can be completed, but the green body object lacks sufficient structural integrity during transfer and sintering
Solution Approach 1:
The binding agent is formulated as a composite material containing multiple components: (meth)acrylic latex binder (1-20 wt%), multi-functional carboxylic acid (0.1-5 wt%), coalescing solvent (10-40 wt%), and water (50-85 wt%). This composite formulation provides enhanced structural integrity through synergistic interactions between components, where the carboxylic acid groups form strong bonds with metal oxide surfaces while the latex matrix provides cohesive strength.
Solution Approach 2:
The invention optimizes specific parameters of the binding agent including molecular weight of carboxylic acid (100-10,000 MW), concentration of carboxylic acid (0.1-5 wt%), and ratio of coalescing solvent to water. These parameter changes enable the binding agent to provide sufficient strength at low concentrations while maintaining processability and green body integrity through controlled evaporation and coalescence.
2Strength
If the binding agent provides strong adhesion to metal particles, then green body strength improves, but automated part extraction becomes difficult
Solution Approach 1:
The binding agent exhibits dynamic properties through the use of coalescing solvents that evaporate over time, transitioning the green body from a loose powder state to a cohesive structure. This dynamic evolution allows for easy extraction when weak and provides structural integrity when needed, resolving the contradiction between extraction ease and green body strength.
Solution Approach 2:
The binding agent is applied in a controlled manner during the printing process, allowing the green body to achieve sufficient strength before extraction is required. The coalescing solvent provides initial workability for extraction while subsequent evaporation and drying provide the necessary strength for handling and sintering.
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 proposed solution enhances the structural integrity of the green body object, allowing for successful automated part extraction and improved strength of the final sintered metal object, as demonstrated by increased mechanical strength in testing.
Implementation Method 1
The binding agent can include from about 0.1 wt % to about 5 wt % multi-functional carboxylic acid having a weight average molecular weight range from about 100 MW to about 1,000 MW
Implementation Method 2
The binder fluid can include latex which can be adhered to the particulate build material, upon coalescence and give the green body object structural integrity
Implementation Method 3
from about 10 wt % to about 40 wt % solvent package including from about 3 wt % to about 40 wt % of a coalescing solvent
Implementation Method 4
from about 40 wt % to about 88 wt % water
Implementation Method 5
heating the individually patterned layers to drive off water and further solidify the individually patterned layers
Implementation Method 6
a three-dimensional printing kit can include a particulate build material including from about 80 wt % to about 100 wt % metal particles
Data Source
AI summary
The present disclosure relates to a binding agent for printing a 3D green body object. The binding agent includes from about 0.3 wt % to about 3 wt % multi-functional carboxylic acid having a weight average molecular weight range from about 100 MW to about 1,000 MW, from about 2 wt % to about 20 wt % a (meth)acrylic latex binder, from about 10 wt % to about 40 wt % solvent package including from about 3 wt % to about 40 wt % of a coalescing solvent, and from about 40 wt % to about 88 wt % water. The weight percentage ranges are based on total content of the binding agent.