Cyclic Oligomer Powder for High-Temperature 3D Printing
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Solution Overview
Problem
Current rapid prototyping and manufacturing methods using thermoplastics are limited by the inability to process materials with melting points above 200°C, leading to components that are not temperature-stable enough for applications above 120°C, due to the 'curl effect' and restricted material selection.
Innovation Solution
A layer-by-layer processing method using powders with at least 50% cyclic oligomers, where selective areas are melted with electromagnetic energy, allowing for the production of components with improved thermal stability and reduced cavity formation, by preheating the build space and optimizing energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional thermoplastics with melting points below 200°C are used in layer-by-layer rapid prototyping, then the process can be easily implemented with standard equipment, but the resulting components lack thermal stability for applications above 120°C
Solution Approach 1:
The invention changes the material parameter from conventional thermoplastics to cyclic oligomers with significantly higher melting points (above 200°C). This parameter change enables the production of components with enhanced heat resistance while maintaining compatibility with standard rapid prototyping equipment and processes, thus resolving the contradiction between heat resistance and ease of manufacture
Solution Approach 2:
The invention uses cyclic oligomers as a composite material alternative to conventional thermoplastics. These cyclic oligomers exhibit both high melting points (enabling heat resistance above 120°C applications) and favorable processing characteristics that allow them to be successfully processed using standard layer-by-layer rapid prototyping methods
2Temperature
If the build space temperature is kept low to avoid the curl effect, then conventional thermoplastics can be processed, but components cannot be produced with improved thermal stability
Solution Approach 1:
By changing from conventional thermoplastics to cyclic oligomers, the invention enables processing at elevated build space temperatures (above 200°C). This parameter change simultaneously achieves two goals: maintaining layer flatness during processing and producing components with superior thermal stability for high-temperature applications
Solution Approach 2:
The invention applies preliminary heating of the build space to temperatures above 200°C before processing. This preliminary action prevents the curl effect that occurs with conventional thermoplastics at low temperatures, while enabling the cyclic oligomers to form components with enhanced thermal stability without distortion
3Strength
If standard rapid prototyping methods are used with conventional powders, then production is simple and fast, but cavity formation occurs and mechanical properties are limited
Solution Approach 1:
The invention employs cyclic oligomers as an advanced composite material that delivers superior mechanical properties and reduced cavity formation. Despite these enhanced performance characteristics, the material remains compatible with standard rapid prototyping processes, maintaining production simplicity and speed without requiring complex process modifications
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 method produces components with significantly higher heat resistance and reduced cavity formation, comparable to conventional polyamide 12 powders, while maintaining mechanical properties similar to injection-molded polymers, enabling applications above 120°C.
Implementation Method 1
plastic powders are selectively briefly exposed to a laser beam in a chamber, causing the powder particles hit by the laser beam to melt
Implementation Method 2
The energy input is achieved via electromagnetic radiation
Implementation Method 3
the energy required for fusion is introduced by a microwave generator
Implementation Method 4
Both methods work with a flat infrared heater to melt the powder
Data Source
AI summary
The present invention relates to a three-dimensional, powder-based manufacturing process using powder consisting essentially of cyclic oligomers, and to shaped bodies produced by this process. The shaping processes are layer-by-layer processes that utilize powders consisting essentially of cyclic oligomers, wherein areas of the respective layer are selectively melted by the application of electromagnetic energy. Selectivity can be achieved—without limiting the invention to this—by masks, the application of inhibitors, absorbers, or susceptors, or by focusing the energy input, for example, using laser technology. After cooling, the solidified areas can be removed from the powder bed as shaped bodies. The process according to the invention uses powder consisting essentially of cyclic oligomers. The precursors are very easy to mill.The component properties, measured on components according to the invention, manufactured using one of the described methods, in particular the density and heat resistance, are improved and enable entry into new application areas.