3D Printed Composite Compression for Strength and Appearance

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Solution Overview

Problem

3D printed molded articles often suffer from inferior compressive strength and appearance due to varying fiber orientation and void ratios when compressed with other materials.

Innovation Solution

Setting the void ratio of the 3D printed shaped article within a predetermined range of 5 to 30% and using a combination of resin and continuous reinforcing fibers, with specific processing conditions such as pressure and temperature, to maintain fiber orientation during compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a shaped article formed by 3D printer is compressed together with other resin material, then productivity and design flexibility are improved, but compressive strength becomes insufficient

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcompressive strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The invention changes the physical-chemical parameters of the resin material, specifically setting the gel fraction to 5-80% and incorporating silane-modified polyester resin. This parameter optimization enables the material to achieve both good compressive strength and bonding strength when compressed, resolving the contradiction between manufacturing efficiency and compressive strength requirements

Inventive Principle:

Principle #35Parameter changes

2Strength

If filament containing continuous reinforcing fibers is used for 3D printing, then strength is improved, but fiber orientation varies during compression causing inferior appearance

Engineering Contradiction:

ImprovestrengthVSAvoidfiber orientation control

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The invention uses composite materials consisting of silane-modified polyester resin and glass fibers (continuous reinforcing fibers). The specific composition ratio and material properties ensure that fibers maintain their orientation during compression while providing enhanced strength, thus resolving the contradiction between strength improvement and fiber orientation control

Inventive Principle:

Principle #40Composite materials

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 results in molded articles with high compressive strength and excellent appearance by effectively rearranging fibers during the compression process.

Implementation Method 1

it has become clear that gelation of a resin by a condensation reaction or the like can promote bonding between a shaped article and another material

Methodology Applied

Scientific EffectCondensation reaction: Condensation

Implementation Method 2

gelation of a resin by a condensation reaction or the like can promote bonding between a shaped article and another material

Methodology Applied

Scientific EffectGelation:

Implementation Method 3

compressing a second material containing a resin and continuous reinforcing fibers against the shaped article

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11465370B2Method for manufacturing molded article and manufacturing device

Publication Date: 2022.10.11 MITSUBISHI GAS CHEM CO INC

AI summary

Provided are: a method for manufacturing a molded article having high compressive strength and excellent appearance by compressing a shaped article obtained using a 3D printer, and a material containing another resin; and a manufacturing device for the same. The method for manufacturing a molded article includes: shaping a filament containing a resin and continuous reinforcing fibers using a 3D printer; and manufacturing a molded article by compressing a second material containing resin against a shaped article formed by the shaping, wherein the shaped article has a void ratio of from 5 to 30%.