3D Printing Coalescing Agent for Uniform Fusing
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Solution Overview
Problem
Current 3D printing technologies face challenges in achieving uniform cosmetic and improved mechanical properties of 3D objects due to limitations in coalescing agents, particularly with regards to dynamic surface tension and radiation absorbance efficiency.
Innovation Solution
A 3D printing system and method utilizing a coalescing agent with a co-solvent, surfactant, and polymerically dispersed carbon black pigment, which has a hydrophilic lipophilic balance (HLB) value less than 10, and a balance of water, applied via an inkjet applicator and exposed to electromagnetic radiation to selectively fuse polymer build materials, enhancing radiation absorbance and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional coalescing agents are used in 3D printing, then the process can be completed, but the cosmetic uniformity and mechanical properties of the 3D objects are insufficient
Solution Approach 1:
The coalescing agent is formulated as a composite material containing multiple components: carbon black particles (for radiation absorption), surfactant (for surface tension control and uniform distribution), and co-solvent (for proper solubility and evaporation characteristics). This composite structure allows simultaneous achievement of cosmetic uniformity through surfactant-mediated distribution and mechanical strength through controlled radiation absorption and fusion.
Solution Approach 2:
The invention optimizes specific parameters of the coalescing agent including carbon black particle size distribution (affecting radiation absorption efficiency), surfactant concentration (controlling surface tension and spreadability), and co-solvent composition (influencing evaporation rate and final uniformity). By precisely controlling these parameters, both cosmetic appearance and mechanical properties are improved.
2Strength
If higher amounts of coalescing agent are used to improve mechanical properties, then strength increases, but cosmetic uniformity deteriorates due to poor distribution
Solution Approach 1:
The surfactant acts as an intermediary substance that mediates between the coalescing agent components and the polymer build material. It reduces surface tension, enables uniform distribution of carbon black particles throughout the polymer matrix, and ensures consistent radiation absorption without aggregation. This intermediary action allows use of adequate coalescing agent amounts for strength while maintaining cosmetic uniformity.
3Productivity
If carbon black pigment is added to enhance radiation absorbance, then fusion efficiency improves, but the formulation complexity and manufacturing difficulty increase
Solution Approach 1:
The invention extracts and isolates the radiation-absorbing function to carbon black particles, which are added as a discrete component to the coalescing agent formulation. This separation allows optimization of radiation absorption independently from other functions (surfactancy, solubility), simplifying the overall formulation approach. Each component can be selected and optimized independently for its specific function.
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 results in 3D objects with improved tensile strength, Young's modulus, and strain properties, and better cosmetic uniformity, even when using reduced amounts of the coalescing agent, compared to traditional methods.
Implementation Method 1
the coalescing agent absorbs the electromagnetic radiation and heats up the portion of the build material in contact with the coalescing agent
Implementation Method 2
heats up the portion of the build material in contact with the coalescing agent to fuse the portion of the build material
Implementation Method 3
a surfactant having a hydrophilic lipophilic balance (HLB) value that is less than 10
Implementation Method 4
a co-solvent having a boiling point of less than 300°C
Implementation Method 5
heats up the portion of the build material in contact with the coalescing agent to fuse the portion of the build material
Data Source
Figure 1
Figure 2A~2D
Figure 2E~3
AI summary
A three-dimensional (3D) printing system includes a fabrication bed, a build material to be introduced into the fabrication bed, an inkjet applicator, a coalescing agent to be selectively introduced by the inkjet applicator onto the build material in the fabrication bed, and a radiation source to expose the coalescing agent and the build material in the fabrication bed to electromagnetic radiation. The coalescing agent includes a co-solvent having a boiling point of less than 300C, a surfactant having a hydrophilic lipophilic balance (HLB) value that is less than 10, a carbon black pigment, a polymeric dispersant, and a balance of water.