Composite Filament for FDM Printing Resolves PLA Brittleness
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Solution Overview
Problem
Polylactic acid (PLA) filaments used in FDM printing exhibit brittleness, poor dimensional stability, and surface defects when fused at temperatures below 210°C, and have inadequate adhesion to printing planes, leading to distortion and incomplete reproduction of intended objects.
Innovation Solution
Filaments comprising a composition of 10-90% polyester, 5-90% polyhydroxyalkanoate, 0-5% cross-linking agent, and 0-50% filler agent, specifically designed to enhance breaking strength, adhesion, and dimensional stability, with a dicarboxylic component comprising aromatic and saturated aliphatic units, and a diol component predominantly from saturated aliphatic diols, are used in the FDM printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If polylactic acid filaments are used in FDM printing, then biodegradability and ease of use are maintained, but breaking strength is insufficient and filaments break during movement
Solution Approach 1:
The patent applies composite materials by combining polylactic acid with at least one additional thermoplastic polymer (such as polyethylene terephthalate, polyamide, or polypropylene) to create a composite filament. This composite structure maintains the biodegradability and ease of use of PLA while incorporating the superior strength and flexibility of the additional polymer, thereby preventing filament breakage during FDM printing operations.
2Ease of operation
If polylactic acid filaments are used in FDM printing, then biodegradability is maintained, but dimensional stability is poor and distortion occurs after cooling
Solution Approach 1:
The patent uses composite materials combining PLA with thermoplastic polymers that have better dimensional stability. The additional polymer component compensates for PLA's tendency to distort during cooling, maintaining the intended geometry of printed objects while preserving the biodegradable nature of the composite material.
3Use of energy by stationary object
If polylactic acid filaments are fused at temperatures below 210°C, then energy consumption is reduced, but surface defects appear on printed objects
Solution Approach 1:
The patent modifies the material composition parameter by incorporating thermoplastic polymers with lower melting points or better flow characteristics. This allows the composite filament to be printed at reduced temperatures (below 210°C) while maintaining adequate surface quality, as the additional polymer enhances melt flow and surface finishing capabilities.
4Ease of operation
If polylactic acid filaments are used in FDM printing, then biodegradability is maintained, but adhesion to printing planes is insufficient and faithful reproduction is not guaranteed
Solution Approach 1:
The patent employs composite materials where the additional thermoplastic polymer component provides improved adhesion properties. This enhances the bonding between deposited layers and the printing plane, ensuring faithful reproduction of the three-dimensional model while maintaining the biodegradable characteristic of the composite filament.
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 modified filaments demonstrate improved breaking strength and dimensional stability, ensuring faithful reproduction of objects with reduced surface defects and enhanced adhesion to printing surfaces, maintaining biodegradability and ease of use.
Implementation Method 1
0-5% by weight, preferably 0-1% with respect to the sum of components i.-iv., of at least one cross-linking agent and/or chain extender comprising at least one di- and/or multiple functional group compound containing isocyanate, peroxide, carbodiimide, isocyanurate, oxazoline, epoxy, anhydride, or divinylether groups
Implementation Method 2
The filament is thrust by a toothed wheel through a melting unit provided with a nozzle from which the material in the fused state is deposited
Implementation Method 3
The FDM printing process provides for the deposition of overlapping layers of a filament of thermoplastic material while the latter is in the fused state
Data Source
Figure 1
AI summary
This invention relates to the use of polymer compositions for the production of filaments for use for printing through fused deposition modelling. This invention also relates to the process of printing by fused deposition modelling which uses the said compositions and objects printed which can be obtained by means of the said printing process.