Electroactive Polymer Powder Bed 3D Printing with Adjustable Electrical Properties

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Solution Overview

Problem

Current 3D printing technologies are limited by the range of materials available, which restricts their commercial production capabilities and ability to produce parts with specific electrical properties, hindering their adoption in industries like aviation and medicine.

Innovation Solution

The development of materials kits for 3D printing that include powder bed materials with electroactive polymer particles and a fusing agent containing a radiation absorber, along with a doping agent, allowing for the creation of 3D printed articles with adjustable electrical properties through the use of electromagnetic energy and selective jetting of agents based on a 3D object model.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional 3D printing materials are used, then the printing process is simple, but the range of materials and electrical properties is limited

Engineering Contradiction:

Improverange of materials and electrical propertiesVSAvoidprinting process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent uses composite materials by combining electroactive polymer particles with traditional powder bed materials. This allows the system to print parts with adjustable electrical properties (such as dielectric constants and dissipation factors) while maintaining the simplicity of the powder bed printing process. The composite material approach enables versatile material properties without requiring completely new printing mechanisms.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies parameter changes by varying the composition, concentration, and size of electroactive polymer particles in the powder bed material. By adjusting these parameters, the electrical properties of the printed parts can be controlled and optimized for specific applications, expanding the range of achievable materials while using the existing printing process framework.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional powder bed materials are used, then the manufacturing process is established, but electrical properties cannot be controlled

Engineering Contradiction:

Improveelectrical property controlVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by incorporating electroactive polymer particles that can be selectively distributed within the powder bed material. This allows different regions of the printed part to have different electrical properties, enabling controlled and customized electrical characteristics while maintaining the overall simplicity of the established powder bed manufacturing process.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If new materials with electroactive polymer particles are used, then electrical properties can be adjusted, but material handling complexity increases

Engineering Contradiction:

Improveelectrical property adjustabilityVSAvoidmaterial handling

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent manages material handling complexity by controlling key parameters of the electroactive polymer particles, such as particle size (D50 from 1 μm to 100 μm) and composition. By optimizing these parameters, the materials maintain good flowability and compatibility with existing powder bed handling systems, enabling electrical property adjustability without proportionally increasing handling difficulty.

Inventive Principle:

Principle #35Parameter changes

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 3D printed articles with controlled electrical properties, enhancing their suitability for commercial applications by expanding the range of materials and properties available, such as dielectric constants and dissipation factors, thereby improving their performance in various industries.

Implementation Method 1

a fusing agent including a radiation absorber to selectively apply to the powder bed material... exposing the powder bed to electromagnetic energy to selectively fuse the electroactive polymer particles

Methodology Applied

Scientific EffectRadiation absorption: Absorption (EM radiation)

Implementation Method 2

exposing the powder bed to electromagnetic energy to selectively fuse the electroactive polymer particles... to form a 3D printed article

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS11958982B2Three-dimensional printing

Publication Date: 2024.04.16 PERIDOT PRINT LLC

AI summary

A materials kit for three-dimensional (3D) printing can include a powder bed material including electroactive polymer particles including electroactive polymer having a melting temperature from about 100° C. to about 250° C. and a fusing agent including a radiation absorber to selectively apply to the powder bed material.