Core-Shell Filament for Ceramic Fused Deposition Modeling
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Solution Overview
Problem
Current 3D printing technologies face challenges in processing high-melting-point metals and ceramics due to their inability to maintain flowability and adhesion, leading to issues with mechanical stability and the need for high-temperature binder removal, which complicates the production of complex geometries and high-strength metal or ceramic parts.
Innovation Solution
A filament comprising a core material coated with a thermoplastic polymer shell, where the core contains ceramic material precursors and ultra-low viscosity binders, allowing for improved mechanical stability and easier binder removal at lower temperatures, enabling the production of complex metal or ceramic parts with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-melting-point ceramic materials are used in fused deposition modeling, then the mechanical strength and high-temperature resistance of the printed parts are improved, but the processability deteriorates due to inability to maintain flowability and adhesion at printing temperatures
Solution Approach 1:
The patent introduces a binder material as an intermediary substance that enables ceramic particles to be processed at lower temperatures. The binder acts as a mediating phase that provides flowability and adhesion during printing, allowing ceramic materials to be deposited without requiring the ceramic itself to be melted or softened, thus resolving the contradiction between high strength and processability
Solution Approach 2:
The invention creates a composite material system consisting of ceramic particles dispersed in a binder matrix. This composite approach allows the ceramic component to provide mechanical strength and high-temperature resistance, while the binder component provides processability and flowability, thereby simultaneously achieving both improved strength and ease of manufacture
2Stability of the object's composition
If traditional binder compositions are used for high-melting-point ceramics, then the ceramic particles can be bound together, but the binder removal requires high temperatures which complicates the production process and causes deformation
Solution Approach 1:
The patent modifies the thermal properties of the binder material to enable removal at lower temperatures. By selecting binder materials with lower decomposition temperatures or by formulating composite binders with staged removal characteristics, the process allows binder elimination without subjecting the ceramic part to high temperatures that would cause deformation, thus resolving the contradiction between binder holding capability and manufacturing precision
3Strength
If the ceramic material content is increased to improve part properties, then the mechanical strength and heat resistance are enhanced, but the flowability and adhesion of the extrusion material deteriorate
Solution Approach 1:
The patent optimizes the ratio and composition of ceramic particles to binder material to maintain appropriate rheological properties. By controlling parameters such as ceramic particle size distribution, shape, and volume fraction, along with binder viscosity and composition, the formulation achieves sufficient ceramic content for desired part properties while maintaining flowability and adhesion necessary for extrusion printing
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 core-shell filament configuration enhances mechanical stability, allows for higher ceramic content, and facilitates easier binder removal, resulting in improved processability and part quality with reduced deformation and stress cracks during the 3D printing process.
Implementation Method 1
a filament comprising a core material (CM) coated with a layer of shell material (SM) comprising a thermoplastic polymer
Implementation Method 2
the core contains ceramic material precursors and ultra-low viscosity binders, allowing for improved mechanical stability and easier binder removal
Implementation Method 3
The thermoplastic material is heated to a temperature past its melting and/or glass transition temperature
Data Source
AI summary
The present invention relates to the use of a filament comprising a core material (CM) comprising a ceramic material precursor (CMP)and the core material (CM) is coated with a layer of shell material (SM) comprising a thermoplastic polymer as a support material in a fused filament fabrication process. Further, the invention relates to three-dimensional objects and a process for the preparation thereof.