Thermoplastic Elastomer Powder With IR Cooling Pigments for Sintering
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Solution Overview
Problem
3D printing of thermoplastic elastomers using sintering processes faces challenges due to non-homogeneous temperature distribution in the powder bed, leading to issues like caking, incomplete sintering, mechanical property degradation, and deformation, which affect the quality and precision of printed articles.
Innovation Solution
Incorporating IR cooling pigments with low absorbance into the thermoplastic elastomer powder to reduce temperature sensitivity and spatial heterogeneity, allowing for better thermal balance and a wider processing window.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If IR radiation lamps are used to heat the powder bed, then the powder can be heated to the required temperature for sintering, but temperature homogeneity in the powder bed deteriorates due to surface heating only
Solution Approach 1:
The patent introduces an intermediary substance (pigment or filler) into the powder bed that acts as a thermal mediator. This intermediary absorbs IR radiation and distributes heat throughout the powder bed, converting the surface-heating problem into a distributed heat transfer system that improves temperature homogeneity while maintaining the required sintering temperature.
Solution Approach 2:
The patent changes the optical and thermal parameters of the powder bed by adding pigments or fillers with specific IR absorbance characteristics. This modifies the heat absorption and distribution behavior, transforming the temperature profile from heterogeneous (surface-only heating) to more homogeneous (distributed heating throughout the powder bed).
2Strength
If the powder temperature is increased to improve sintering, then better mechanical properties are achieved, but agglomeration and caking occur
Solution Approach 1:
The patent introduces an intermediary substance (pigment or filler) that mediates the thermal interaction between IR radiation and the polymer powder. This intermediary absorbs and redistributes thermal energy, allowing the powder to reach higher temperatures for improved mechanical properties without experiencing the harmful effects of direct IR heating (agglomeration and caking).
Solution Approach 2:
The patent converts the potentially harmful effect of IR radiation (which causes surface heating and agglomeration) into a beneficial distributed heating mechanism. By introducing pigments or fillers that absorb IR radiation, the harmful surface-concentrated heating is transformed into beneficial distributed thermal energy that promotes uniform sintering without agglomeration.
3Ease of manufacture
If the powder temperature is decreased to prevent agglomeration, then powder spreading is improved, but sintering completeness deteriorates
Solution Approach 1:
The patent introduces an intermediary substance that mediates heat transfer from the IR source to the powder particles. This intermediary enables the powder to be heated uniformly throughout the bed, allowing complete sintering at lower temperatures while maintaining good powder spreading, thereby resolving the trade-off between sintering completeness and powder handling.
4Power
If temperature differences between air and powder surface are large, then heating efficiency is improved, but stress and deformation increase
Solution Approach 1:
The patent introduces an intermediary substance (pigment or filler) that acts as a thermal buffer between the IR radiation source and the powder particles. This intermediary distributes thermal energy more uniformly, reducing temperature gradients between the powder surface and surrounding air, thereby minimizing thermal stresses and deformations while maintaining adequate heating efficiency.
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 quality and precision of 3D printed articles by stabilizing temperature and reducing temporal heterogeneity, facilitating easier and more reliable printing with improved mechanical properties.
Implementation Method 1
pigments having low absorbance of IR rays—also called IR cooling pigments
Implementation Method 2
heated, for example from above by infrared (IR) radiation lamps
Implementation Method 3
localized sintering of grains of powder
Implementation Method 4
selectively melted by an electromagnetic energy source
Data Source
AI summary
The invention is targeted mainly at a polymer powder suitable for 3D printing by sintering, comprising:(a) a polymer composition comprising at least one thermoplastic elastomer;(b) a pigment composition comprising at least one pigment exhibiting an absorbance of the light with a wavelength of 1000 nm, as measured according to the standard ASTM E1790, of less than 50%; and also, if appropriate,(c) one or more fillers or reinforcements; and(d) one or more additional additives.The invention is also targeted at a process for the preparation of said powder and also at the use of said powder for 3D printing by sintering. Finally, it is targeted at the use of a pigment exhibiting an absorbance of the light with a wavelength of 1000 nm, as measured according to the standard ASTM E1790, of less than 50% to improve the definition and/or the mechanical properties of the articles printed by a process of 3D printing by sintering of a thermoplastic elastomer powder.