Core-Shell Resin Powder for 3D Printing Accuracy
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Solution Overview
Problem
Existing resin materials used in powder bed fusion for three-dimensional object fabrication tend to deform at high temperatures, leading to reduced fabrication accuracy due to softening and aggregation issues, which existing powder materials do not adequately address.
Innovation Solution
A powder material with a core-shell structure, where the shell resin has a higher storage modulus than the core resin at specific temperatures, is used, allowing for preheating to a temperature where the core resin softens without excessive deformation, and laser irradiation to fuse the particles with reduced energy, maintaining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If resin materials are used in powder bed fusion, then material versatility is improved, but fabrication accuracy deteriorates due to particle deformation at high temperatures
Solution Approach 1:
The resin particle is segmented into a core resin and a shell resin with different thermal properties. The core resin provides the desired material properties while the shell resin maintains structural integrity at high temperatures, preventing particle deformation and aggregation during the powder bed fusion process.
Solution Approach 2:
The invention uses a composite particle structure where the core resin and shell resin are combined in a single particle. This composite structure allows the particle to exhibit both the desired low-temperature properties of the core resin and the high-temperature stability of the shell resin, resolving the contradiction between material versatility and fabrication accuracy.
2Productivity
If preheating is applied to reduce laser irradiation time, then productivity is improved, but manufacturing precision deteriorates due to particle deformation
Solution Approach 1:
The shell resin is designed to maintain structural integrity at preheating temperatures, allowing the core resin to be preheated without causing particle deformation. This preliminary heating action reduces the energy required for subsequent laser irradiation while maintaining particle shape and fabrication accuracy.
Solution Approach 2:
The invention changes the thermal parameters of the particle by using a shell resin with a higher glass transition temperature than the core resin. This parameter change allows the particle to withstand preheating temperatures without deformation, enabling both high productivity and high precision in the fabrication process.
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 approach enhances the accuracy of three-dimensional object fabrication by minimizing deformation during the lamination and fusion processes, achieving higher precision and reducing volume changes in the resin particles.
Implementation Method 1
a temperature TS(6.5) at which a storage modulus G′ of a material for the shell resin becomes 1×10^6.5 Pa is higher than a temperature TC(6.5) at which a storage modulus G′ of a material for the core resin becomes 1×10^6.5 Pa
Implementation Method 2
irradiating desired positions on the thin layer with a laser to selectively fuse the powder particles
Implementation Method 3
powder bed fusion is known... irradiating desired positions on the thin layer with a laser to selectively fuse the powder particles
Data Source
AI summary
The present invention pertains to a powder material used to manufacture a three-dimensional modeled object by selectively radiating laser light to a thin layer of the powder material including powder particles, forming a modeled object layer obtained by melt-binding of the powder particles, and layering the modeled object layer. The powder particles include a core resin and a shell resin for coating the core resin, the temperature at which the storage modulus G′ of the material constituting the shell resin is 1×106.5 Pa being higher than the temperature at which the storage modulus G′ of the material constituting the core resin is 1×106.5 Pa. The abovementioned powder material, makes it possible to manufacture a three-dimensional modeled object having higher definition.