Bio-derived Polyester Resin for Selective Laser Sintering
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Solution Overview
Problem
Current 3D printing technologies using selective laser sintering (SLS) lack sustainable and cost-effective materials that meet mechanical robustness demands while being environmentally friendly.
Innovation Solution
Development of bio-derived polyester resins comprising 1,4-butanediol and terephthalate monomer units, synthesized from recycled plastics and bio-based sources, which are processed into a powdered form suitable for SLS 3D printing, offering a balance of mechanical properties and environmental sustainability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional SLS materials are used, then mechanical robustness is achieved, but environmental sustainability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the polyester resin by incorporating specific ratios of cyclic diesters (10-40 mol%) and chain diesters (60-90 mol%), creating a new material class that maintains mechanical properties while improving environmental sustainability through bio-based and recycled content
Solution Approach 2:
The invention creates a composite polyester resin system combining different ester types (cyclic and chain diesters) with complementary properties, where the cyclic diesters provide structural integrity and the chain diesters enhance processability, achieving both mechanical robustness and sustainability
2Object-affected harmful factors
If sustainable materials are developed, then environmental footprint is reduced, but material performance consistency deteriorates
Solution Approach 1:
The patent establishes specific compositional parameters (10-40 mol% cyclic diesters, 60-90 mol% chain diesters) and processing parameters (temperature ranges, pressure conditions) that ensure consistent mechanical properties across different batches of sustainable polyester resin materials
Solution Approach 2:
The invention applies different ester components in specific proportions to achieve localized functional optimization, where cyclic diesters provide structural stability in critical load-bearing regions while chain diesters ensure uniform distribution and bonding in other areas
3Object-affected harmful factors
If new polyester resin compositions are synthesized, then material sustainability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the synthesis process into distinct sequential stages: depolymerization of recycled PET, esterification with diols, and polycondensation, allowing each step to be optimized independently and simplifying the overall manufacturing process despite the multi-component nature of the final resin
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 bio-derived polyester resins provide mechanical robustness comparable to commercial materials, with a reduced environmental footprint, and are cost-effective, making them suitable for forming complex three-dimensional objects with removable support materials.
Implementation Method 1
The selective laser sintering (SLS) technique for additive manufacturing (3D printing) uses a rasterized laser to 'scan' over a bed of polymer powder, sintering it to form solid shapes in a layer-wise fashion
Implementation Method 2
uses a rasterized laser to 'scan' over a bed of polymer powder, sintering it
Implementation Method 3
methods of making a polyester resin comprising copolymerizing in the presence of a catalyst a mixture comprising (a) a 1,4-butanediol (BDO) monomer unit and (b) a depolymerized polyethylene terephthalate
Implementation Method 4
sintering it to form solid shapes in a layer-wise fashion
Data Source
AI summary
A composition for use in 3D printing includes a polyester resin including a 1,4-butanediol (BDO) monomer unit and a terephthalate monomer unit, the polyester resin being provided in a powdered form with a particle size in a range from about 100 microns to about 500 microns.