Conductive Fusing Ink for 3D Printed Electrical Traces
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Solution Overview
Problem
Current 3D printing technologies are limited by the range of materials available, which restricts the complexity and functionality of printed parts, especially in terms of incorporating electrically conductive features, and are often expensive.
Innovation Solution
A 3D printing system and material set that uses a thermoplastic polymer powder and conductive fusing ink, where the conductive ink absorbs light energy to melt and coalesce the powder, allowing for the creation of parts with embedded electrical elements and surface features, including conductive traces and vias, using a combination of transition metal particles and fusing agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional 3D printing materials are used, then the printing process is simple, but the electrical conductivity and functionality of printed parts are limited
Solution Approach 1:
The patent uses composite materials by combining thermoplastic polymer powder with conductive ink containing transition metal particles. This composite approach enables the printed parts to achieve electrical conductivity while maintaining the structural properties of the polymer matrix, thereby resolving the contradiction between material versatility and functional performance.
Solution Approach 2:
The conductive ink is applied selectively to specific regions of the powder bed where electrical conductivity is required. This local application strategy allows conventional polymer materials to be used for the bulk structure while introducing conductive properties only where needed, thus improving electrical functionality without requiring a complete change of material system.
2Ease of manufacture
If selective laser sintering is used, then complex parts can be manufactured, but the system cost is very expensive
Solution Approach 1:
The patent replaces the expensive laser-based heating system with an inkjet printing system that deposits conductive ink followed by a more affordable heating process. This substitution maintains the capability to manufacture complex parts with embedded electrical features while significantly reducing system cost by using commercially available inkjet technology instead of specialized laser equipment.
Solution Approach 2:
The conductive ink serves as an intermediary material that enables electrical functionality and facilitates the bonding process. By introducing this intermediate substance, the system achieves complex part manufacturing capabilities at lower cost, as the ink acts as both a functional additive and a bonding agent during the heating process.
3Adaptability or versatility
If standard manufacturing techniques are used, then production costs are lower, but complex electrical configurations cannot be created
Solution Approach 1:
The patent merges multiple manufacturing functions into a single 3D printing process. The conductive ink is deposited and bonded simultaneously with the polymer powder in one integrated process, allowing complex electrical configurations to be created directly during printing rather than requiring separate post-processing steps. This merging enables design flexibility while controlling production costs through process integration.
Solution Approach 2:
The patent adds the electrical conductivity dimension to the traditional 3D printing process by incorporating conductive ink. This enables the creation of parts with embedded electrical features, traces, and vias that have functionality in the electrical dimension, thereby achieving complex electrical configurations without significantly increasing manufacturing complexity or cost.
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
Enables the rapid and accurate creation of 3D parts with complex electrical configurations not possible with standard manufacturing techniques, offering high conductivity and flexibility in design while reducing production costs.
Implementation Method 1
The fusing ink absorbs more energy from the light than the unprinted powder. The absorbed light energy is converted to thermal energy
Implementation Method 2
The absorbed light energy is converted to thermal energy, causing the printed portions of the powder to melt and coalesce
Implementation Method 3
a powder bed is exposed to point heat from a laser to melt the powder wherever the object is to be formed
Implementation Method 4
selective heating via electromagnetic energy with a wavelength of from 100 nm to 1 mm
Implementation Method 5
causing the printed portions of the powder to melt and coalesce. This forms a solid layer
Data Source
Figure 1
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AI summary
The present disclosure is drawn to material sets for 3-dimensional printing, 3-dimensional printing systems, and 3-dimensional printed parts. A material set can include a thermoplastic polymer powder having an average particle size from 20 ?m to 100 ?m, a conductive fusing ink comprising a transition metal, and second fusing ink. The second fusing ink can include a fusing agent capable of absorbing electromagnetic radiation to produce heat. The second fusing ink can provide a lower conductivity than the conductive fusing ink when printed on the thermoplastic polymer powder.