Bright NIR-Absorber Plastic Powder for Uniform 3D Printing
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Solution Overview
Problem
Existing additive manufacturing methods using NIR absorbers in plastic powders face issues of uneven heating, demixing of particles, and poor layer bonding, leading to inadequate mechanical properties and process instability.
Innovation Solution
Incorporating small particle size (≤ 10 µm) bright NIR radiation-absorbing materials at 0.01 to 1.4 wt.% into the plastic powder ensures uniform energy transfer and effective layer bonding, reducing the risk of hotspots and improving mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If absorbers are added to polymer-based powders to enable melting with mid- or near-infrared lasers, then the adaptability to different laser wavelengths is improved, but the manufacturing precision and layer bonding quality deteriorate
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size of absorbers to ≤10 μm and controlling the concentration at 0.01 to 1.4 wt.%. These parameter adjustments ensure uniform energy distribution during NIR laser exposure, enabling effective layer bonding while maintaining adaptability to different laser wavelengths. The small particle size prevents localized overheating and ensures homogeneous melting.
Solution Approach 2:
The patent uses composite materials by incorporating NIR-absorbing particles into polymer-based powders. This composite structure combines the laser-absorbing properties of the additive material with the structural properties of the polymer, enabling the use of mid- or near-infrared lasers while maintaining good layer bonding and manufacturing quality.
2Productivity
If absorber concentration is increased to improve melting efficiency, then the productivity increases, but the temperature uniformity and polymer degradation worsen due to excessive heating
Solution Approach 1:
The patent applies parameter changes by precisely controlling the absorber concentration within 0.01 to 1.4 wt.% and particle size to ≤10 μm. This optimization achieves a balance where sufficient absorbers are present to enable efficient melting and improve productivity, while the low concentration and small size prevent excessive localized heating and maintain temperature uniformity throughout the powder layer.
3Ease of manufacture
If absorbers are mixed into powder as a dry blend to enable NIR melting, then the ease of manufacture improves, but the reliability of the sintering process deteriorates due to demixing and process instability
Solution Approach 1:
The patent applies parameter changes by controlling the particle size of absorbers to ≤10 μm, which is comparable to or smaller than the polymer particles. This size matching, combined with optimized concentration (0.01 to 1.4 wt.%), ensures uniform distribution of absorbers throughout the powder blend, preventing demixing during handling and sintering, and thereby improving process reliability while maintaining ease of manufacture.
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 achieves homogeneous meltability and improved layer bonding, resulting in three-dimensional objects with enhanced mechanical properties and process stability.
Implementation Method 1
the plastic powder contains incorporated particles of a bright NIR radiation-absorbing material... By exposing the absorbers to light, the heat developed in the absorber can be used to melt the polymer-based particles
Implementation Method 2
the heat developed in the absorber can be used to melt the polymer-based particles
Implementation Method 3
a CO2 laser with a wavelength of 10,600 nm is typically used... laser diodes, which can be arranged in a cell-like manner
Implementation Method 4
melting/solidifying layer regions using electromagnetic radiation... the heat developed in the absorber can be used to melt the polymer-based particles
Implementation Method 5
selective sintering using electromagnetic radiation... methods for producing three-dimensional objects (molded bodies) by selective sintering
Data Source
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AI summary
The present disclosure relates to plastic powder for use as a building material for the additive production of three-dimensional objects by exposure to electromagnetic radiation, wherein the plastic powder contains incorporated particles of a bright NIR radiation-absorbing material with an average particle size D50, as determined by laser diffraction, of ≤ 10 µm, in an amount of 0.01 to 1.4 wt. %. The present disclosure further relates to methods for producing corresponding plastic powders, methods for producing three-dimensional objects in which corresponding plastic powders are used as a building material, and three-dimensional objects produced by corresponding methods, as well as systems configured for processing corresponding plastic powders to such an extent that the plastic powder is present in a storage container of the system.