3D Ceramic Printing via Binder Dissolution for High Density
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Solution Overview
Problem
Existing methods for producing three-dimensional ceramic objects struggle to achieve high accuracy and high-density ceramic sintered bodies, often resulting in internal flaws, cracking, and deformation during heat treatment.
Innovation Solution
A three-dimensional object producing method that granulates ceramic primary particles into secondary particles with a binder resin, forms layers, and applies a liquid to dissolve the binder, promoting densification and reducing voids, using an inkjet method for precise application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If resin powder is used for producing three-dimensional objects, then complicated shapes can be formed, but high-density ceramic sintered bodies cannot be obtained
Solution Approach 1:
The invention segments the particle structure into primary particles (5 μm or less, preferably 0.01-1 μm) and secondary particles formed by aggregating multiple primary particles with binder resin. This segmentation allows the secondary particles to be handled as unified units for forming complicated three-dimensional shapes, while the fine primary particles ensure high density after sintering by filling voids effectively.
Solution Approach 2:
The invention uses composite secondary particles consisting of ceramic primary particles combined with binder resin. This composite structure enables the particles to maintain structural integrity during handling and forming of complicated shapes, while the binder resin dissolves during sintering, leaving the primary particles to form high-density ceramic structures.
2Ease of manufacture
If conventional methods are used to produce ceramic sintered bodies, then production can proceed with standard materials, but internal flaws and cracking occur during heat treatment
Solution Approach 1:
The invention changes the critical parameter of primary particle size to 5 μm or less (preferably 0.01-1 μm). This parameter change ensures that particles are fine enough to fill voids effectively during sintering, preventing internal flaws and cracking while maintaining ease of manufacture through a straightforward process of forming layers and dissolving binder resin.
Solution Approach 2:
The invention performs preliminary action by pre-forming secondary particles with binder resin that will dissolve during the forming process. This preliminary structuring allows the green body to maintain integrity during handling while ensuring that the binder will completely dissolve during sintering, preventing internal flaws and cracking without requiring complex post-processing.
3Ease of manufacture
If binder resin is used to form layers, then particles can be bound together, but voids and low density result after binder dissolution
Solution Approach 1:
The invention applies local quality by using binder resin specifically at the interfaces between primary particles within secondary particles. The binder resin provides localized binding where needed to maintain particle aggregation during handling, while the fine primary particles (5 μm or less) ensure that when the binder dissolves, the local void spaces are minimized and can be effectively filled during sintering.
Solution Approach 2:
The invention uses a nested structure where multiple primary particles (0.01-1 μm) are aggregated to form secondary particles with binder resin. This nesting allows the fine primary particles to be contained within the secondary particle structure, ensuring that when the binder dissolves, the nested primary particles remain in close proximity and can sinter into high-density structures without creating large voids.
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 highly accurate, high-density ceramic sintered bodies with reduced internal flaws and deformation, suitable for complex shapes and large structural parts without cracking, ensuring high shape accuracy and strength.
Implementation Method 1
applying a liquid for dissolving the binder resin to the layer formed in the forming step
Data Source
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AI summary
Provided is a three-dimensional object producing method for producing a three-dimensional object using primary particles containing at least a ceramic material, the three-dimensional object producing method including: a forming step of forming a layer using secondary particles containing the primary particles and a binder resin; and an applying step of applying a liquid for dissolving the binder resin to the layer formed in the forming step, wherein a central particle diameter of the primary particles is 5 micrometers or less, wherein the liquid contains inorganic particles.