Coreactive 3D Printing Compositions for Clog-Free High-Speed Deposition

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Solution Overview

Problem

Existing additive manufacturing methods using coreactive materials face challenges in controlling the reaction rate and viscosity of reactive components, leading to issues such as nozzle clogging and compromised structural integrity of printed objects.

Innovation Solution

A method involving the use of coreactive compositions, where two reactive components are pumped through a mixer and deposited to form extrudates, allowing for controlled reaction and viscosity during deposition, enabling faster printing rates and improved structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If coreactive compositions are used in additive manufacturing, then manufacturing productivity is improved, but the reaction rate and viscosity control becomes difficult leading to nozzle clogging

Engineering Contradiction:

Improvemanufacturing speedVSAvoidnozzle clogging

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The coreactive composition is divided into two separate components (first component and second component) that are pumped through separate pumps and only mixed in the deposition nozzle just before deposition. This segmentation prevents premature reaction and viscosity increase in the supply system, avoiding nozzle clogging while enabling fast deposition when the components are combined at the target location.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The two reactive components are prepared and positioned in advance in separate pumps and delivery systems, but the actual mixing and reaction occur only at the moment of deposition. This preliminary preparation allows the system to be ready for fast deposition without having suffered from premature reaction effects.

Inventive Principle:

Principle #10Preliminary action

2Strength

If coreactive compositions are used to form strong structures, then structural integrity is improved, but reaction rate control becomes difficult compromising print quality

Engineering Contradiction:

Improvestructural integrityVSAvoidprint quality

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

By separating the two reactive components into different pumps and delivery lines, the system maintains precise control over when and where the reaction occurs. The components remain stable individually during storage and transport, then react immediately upon mixing in the nozzle, ensuring both strong structural integrity and precise print quality without premature reaction effects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mixing mechanism in the deposition nozzle acts as an intermediary that controls the reaction timing. The nozzle design and mixing mechanism ensure that the two components are combined precisely at the deposition point, allowing controlled reaction rate that produces strong structures while maintaining print precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If filler content is increased to enhance material properties, then mechanical and electrical properties are improved, but viscosity increases causing deposition problems

Engineering Contradiction:

Improvemechanical propertiesVSAvoiddeposition capability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The filler-containing composition is maintained as a separate component that only mixes with the other component in the deposition nozzle. This allows high filler content (for enhanced mechanical and electrical properties) without premature viscosity increase that would prevent deposition. The low-viscosity component can be pumped easily, and the high filler content component is added just before deposition when mixing occurs.

Inventive Principle:

Principle #1Segmentation

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 enables the production of stronger, higher filler content objects with enhanced mechanical and electrical properties, such as solvent resistance, electrical conductivity, and thermal conductivity, while facilitating high deposition speeds and maintaining shape integrity.

Implementation Method 1

pumping the first component from the first pump, and pumping the second component from the second pump through a mixer to provide a coreactive composition

Methodology Applied

Scientific EffectMixing: