Thermoplastic Elastomer Granules for Precise Flexible 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing three-dimensional printing technologies using thermoplastic elastomers face issues with gear engagement and require post-molding dissolution of reinforcing portions, leading to quality degradation and difficulty in achieving high precision and flexibility in molded objects.
Innovation Solution
A granular material formed of thermoplastic elastomer with specific viscoelastic properties, allowing direct extrusion without reinforcing portions, and a filament with continuous reinforcing fibers and shape memory polymer for enhanced restoring force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a linear reinforcing portion is added to the filament to enable gear engagement, then the filament can be fed properly, but the reinforcing portion must be dissolved after molding which degrades the quality of the molded object
Solution Approach 1:
The patent removes the linear reinforcing portion from the filament structure entirely, replacing it with granular filler particles dispersed within the thermoplastic elastomer matrix. This extraction eliminates the need for post-molding dissolution steps while maintaining proper filament feeding through the gear mechanism, as the granular structure provides sufficient friction and engagement surfaces.
Solution Approach 2:
The patent changes the physical state of the reinforcing component from a continuous linear structure to discrete granular particles with specific size parameters (0.1-2.0 mm diameter). This parameter change allows the filler to be embedded within the elastomer matrix, providing gear engagement through surface friction and mechanical interlocking without requiring post-processing removal.
2Adaptability or versatility
If the distance between line portions is widened to increase flexibility, then the molded object becomes more flexible, but the shape tends to collapse making high precision molding difficult
Solution Approach 1:
The patent creates a composite material system combining thermoplastic elastomer with granular filler particles. The elastomer matrix provides the necessary flexibility and elasticity, while the dispersed filler particles provide structural support and rigidity. This composite structure enables the molded object to maintain its shape at wider line portion distances while retaining flexibility, resolving the contradiction between flexibility and shape stability.
Solution Approach 2:
The patent applies local quality by distributing granular filler particles throughout the thermoplastic elastomer matrix at specific concentrations (1-50 wt%). This creates regions of enhanced rigidity within the flexible matrix, allowing the material to maintain structural integrity and shape at wider line spacing while preserving overall flexibility for elastic recovery.
3Manufacturing precision
If granular material is used instead of filament, then reinforcing portions are not needed, but the material must be extruded from granular form
Solution Approach 1:
The patent changes the physical form parameter of the molding material from continuous filament to granular particles with controlled size distribution (0.1-2.0 mm). This granular form factor enables the material to be processed through conventional extruder screws and fed through standard nozzle diameters (0.2-1.0 mm) used in FDM 3D printers, making the manufacturing process as easy as filament while eliminating the need for reinforcing portions.
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
Enables the production of flexible molded objects with high precision and restoring force, eliminating the need for post-molding dissolution and improving molding accuracy.
Implementation Method 1
the thermoplastic elastomer has, at at least one of the measurement temperature of 120 to 270° C., a loss tangent tan δ of 0.40 or more and a loss modulus G′′ of 11000 Pa or less
Implementation Method 2
a running step of running a strand formed by extruding, from a nozzle, the granular material melted in an extruder with a screw
Implementation Method 3
a filament with continuous reinforcing fibers and shape memory polymer for enhanced restoring force
Data Source
AI summary
A granular material for a fused deposition three-dimensional printer that enables a flexible molded object to be manufactured with high precision. A granular material for a fused deposition three-dimensional printer is provided. The granular material is formed of a thermoplastic elastomer, and the thermoplastic elastomer has, at at least one of the measurement temperature of 120 to 270° C., a loss tangent tan δ of 0.40 or more and a loss modulus G″ of 11000 Pa or less, which are measured with a rotary rheometer having a pair of parallel plates with a diameter of 20 mm and a measurement gap of 1.3 mm at a frequency of 1 Hz.