3D Printing Ceramic Granules via Extrusion Comminution
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Solution Overview
Problem
Existing methods for producing granulates suitable for 3D printing and subsequent ceramization are complex and do not efficiently produce near-net-shape ceramic components, often requiring mechanical reworking.
Innovation Solution
A method involving the mixing of a binder material, plasticizer material, and fillers, with optional surfactants, to create a compound material that is extruded and then comminuted into granules, optimizing flowability and printability, and allowing for homogeneous distribution of these components during the 3D printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce granulates for 3D printing, then the production process is complex, but the manufacturing precision and quality of ceramic components are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the granulate by incorporating specific plasticizer materials (polyethylene glycol with molecular masses of 200-6000 g/mol) and surface-active materials (stearic acid) in optimized proportions (1-5% by weight based on binder material mass). These parameter changes improve the flowability and printability of the granulates, enabling production of high-quality near-net-shape ceramic components through a standardized extrusion-based 3D printing process
Solution Approach 2:
The patent creates a composite granulate material system consisting of binder material granules (thermoplastic polymers), plasticizer materials, surface-active materials, and fillers. This composite structure allows the plasticizer and surfactant to coat the binder granules, improving interparticle lubrication and flow characteristics. The composite material approach enables simultaneous achievement of good flowability, green body strength, and final ceramic quality without requiring complex post-processing steps
2Ease of operation
If granulates are produced with improved flowability, then printability is enhanced, but the distribution homogeneity of plasticizer and surfactant materials becomes challenging
Solution Approach 1:
The patent applies preliminary action by pre-coating the binder material granules with plasticizer and surface-active materials before mixing with fillers. This is achieved by adding the plasticizer and surfactant to the binder granules first, allowing them to adsorb onto the granule surfaces. This preliminary coating ensures homogeneous distribution throughout the final granulate mixture and prevents agglomeration during the 3D printing process, thereby maintaining both printability and compositional homogeneity
3Productivity
If mechanical reworking is reduced through near-net-shape production, then productivity increases, but the green body strength and structural integrity become critical
Solution Approach 1:
The patent uses plasticizer materials (particularly polyethylene glycol) and surface-active materials as intermediary substances that remain in the green body during 3D printing and subsequent drying. These intermediaries provide temporary binding and structural support to the green body, enhancing its mechanical strength and structural integrity. The plasticizers act as lubricants between particles, improving green body strength without compromising the final ceramic quality after sintering, thereby enabling near-net-shape production with high productivity
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 method enables the production of granulates that can be easily 3D-printed into near-net-shape green bodies, which can be ceramized, reducing the need for mechanical reworking and improving the quality and porosity of the resulting ceramic components.
Implementation Method 1
the plasticizer material and/or the surface-active material forms a coating on the binder material and/or on a mixture of the binder material and the one or more fillers
Implementation Method 2
polymeric components of the binding material and/or the plasticizer material are preferably melted
Implementation Method 3
The extruded compound material is comminuted, for example pelletized, to form the granules
Data Source
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AI summary
A method for producing a granulate (100) is provided, wherein, according to the method, a binder (102), a plasticizer material and/or a surfactant material (104) and one or more fillers (112) are mixed, forming a compound material, wherein the compound material (118) is extruded and wherein the extruded compound material (118) is comminuted to form the granulate (100).