Coated Polymer Powder for Dielectric Inter-Particle Fusion
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Solution Overview
Problem
Powder-based additive manufacturing techniques like SLS and SLM introduce voids between powder particles, reducing the structural integrity of the final object due to inadequate inter-layer bonding.
Innovation Solution
A coated powder is developed with a base polymer layer and a coating polymer layer, where the coating polymer layer has a higher dielectric loss factor than the base polymer layer, allowing for selective dielectric heating to enhance inter-layer bonding and structural integrity through the use of electromagnetic radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional powder-based additive manufacturing (SLS/SLM) is used, then manufacturing capability is achieved, but voids form between powder particles reducing structural integrity
Solution Approach 1:
The powder particles are segmented into a core component and a shell component. The core provides the base material properties while the shell is engineered with specific dielectric properties to enhance inter-layer bonding and eliminate voids during the additive manufacturing process.
Solution Approach 2:
The invention changes the dielectric loss factor parameter of the powder particles by coating them with a material having a higher dielectric loss factor than the core. This parameter change enables selective dielectric heating of the shell, improving inter-layer bonding and reducing voids.
2Reliability
If a coating layer with higher dielectric loss factor is applied, then inter-layer bonding is enhanced, but manufacturing process complexity increases
Solution Approach 1:
The invention changes the dielectric loss factor parameter of the powder particles by coating them with a material having a higher dielectric loss factor than the core. This parameter change enables selective dielectric heating of the shell, improving inter-layer bonding and reducing 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
The coated powder promotes improved structural integrity by facilitating inter-layer chain diffusion and bonding, reducing voids between particles and build layers, resulting in a stronger and more cohesive final object.
Implementation Method 1
a coating polymer layer surrounding the base polymer layer and formed of a coating polymer material having a second dielectric loss factor, wherein the second dielectric loss factor of the coating polymer material is greater than the first dielectric loss factor of the base polymer material
Data Source
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AI summary
A coated powder for use in additive manufacturing includes a base polymer layer formed of a base polymer material and a coating polymer layer formed of a coating polymer material. At least the coating polymer material is susceptible to dielectric heating in response to electromagnetic radiation, thereby promoting fusion between adjacent particles of coated powder that are deposited during the additive manufacturing process. Specifically, when electromagnetic radiation is applied to at least an interface area between adjacent particles of coated powder, the polymer coating layer melts to diffuse across the interface area, thereby preventing formation of voids. The base polymer material and the coating polymer material also may have similar melting points and compatible solubility parameters to further promote fusion between particles.