Shaping Composition for Copper 3D Print Sag Resistance
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Solution Overview
Problem
During the heat-fusing process in 3D printing of copper-containing build materials, the binding agent is not effective at intermediate temperatures, leading to sagging of cantilevered or spanned regions in green body objects before they become fully fused, as it burns off or loses binding capability before the copper particles start to fully fuse.
Innovation Solution
A three-dimensional printing kit and method that includes a shaping composition applied to the green body object, comprising metal shaping particles smaller than the copper-containing build particles, which interact with the copper particles at intermediate temperatures to provide sag resistance and support, allowing the object to maintain shape during heat-fusing, resulting in a fused metal object with a metal coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a binding agent is used to hold copper-containing build particles together in a green body object, then the green body object can be formed and handled, but the binding agent burns off or loses binding capability at intermediate temperatures during heat-fusing, causing sagging of cantilevered or spanned regions
Solution Approach 1:
A shaping composition is applied as an intermediary layer between the binding agent and the external environment. This shaping composition remains effective at intermediate temperatures (below the copper melting point) and provides structural support during the temperature ramp-up phase, preventing sagging before the binding agent needs to maintain strength at high temperatures.
Solution Approach 2:
The solution involves changing the temperature parameter profile during heat-fusing, specifically controlling the ramp-up rate through the intermediate temperature range. By managing the temperature progression and using a shaping composition designed for intermediate temperature stability, the green body maintains shape stability during the critical transition phase before full sintering.
2Productivity
If the temperature is ramped up quickly to achieve fast heat-fusing, then productivity increases, but the green body object sags or deforms at intermediate temperatures before particles fully fuse
Solution Approach 1:
A shaping composition is applied to the green body object before heat-fusing begins. This preliminary action prepares the object to resist deformation during the subsequent temperature ramp-up, allowing faster heating rates without sacrificing shape accuracy, as the shaping composition provides temporary structural support during the critical intermediate temperature phase.
3Ease of manufacture
If the green body object is made with larger copper-containing build particles, then ease of manufacture improves, but the object becomes more prone to sagging at intermediate temperatures due to weaker inter-particle bonding
Solution Approach 1:
The green body object is enhanced by incorporating a shaping composition that creates a composite structure. This shaping composition fills spaces between larger copper-containing build particles and provides additional bonding and structural support at intermediate temperatures, effectively creating a composite material system where the shaping composition compensates for the weaker inter-particle bonding inherent in larger particle systems.
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 shaping composition effectively counteracts temperature-induced deformation, enabling the retention of the green body object's shape during heat-fusing, reducing sagging and allowing for the formation of a fused metal object with a metal coating that provides additional strength and stability.
Implementation Method 1
metal shaping particles smaller than the copper-containing build particles, which interact with the copper particles at intermediate temperatures
Implementation Method 2
ramping-up the temperature applied to the green body object though an intermediate temperature range where the metal shaping particles interact with copper-containing build particles of the green body object
Implementation Method 3
fusing the green body object at a heat-fusing temperature above the intermediate temperature range to form a fused metal object
Data Source
AI summary
A three-dimensional printing kit can include a particulate build material with from about 80 wt % to 100 wt % copper-containing build particles having a D50 particle size distribution value from about 1 μm to about 150 μm, a binding agent including a build binder to apply to particulate build material layers to form a green body object, and a shaping composition to apply to a surface of the green body object and to control green body object deformation. The shaping composition can include from about 10 wt % to about 80 wt % liquid vehicle and from about 20 wt % to about 90 wt % metal shaping particles having a D50 particle size distribution value from about 100 nm to about 100 μm. The metal shaping particles can be smaller than the copper-containing build particles.