Epoxide-Modified Polyalkylene Powder for High-Strength 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The limitations of 3D printing technology in commercial production due to the restricted range of materials used, which hinders its widespread adoption in industries like aviation and medicine, where high-strength, customized parts are required.
Innovation Solution
A 3D printing kit and system utilizing a powder bed material comprising polyalkylene particles with grafted epoxide moieties, combined with a fusing agent and hardener, that undergoes both thermal fusion and chemical crosslinking to produce articles with high mechanical strength, leveraging a radiation absorber to convert electromagnetic energy into heat for fusion and a hardener for crosslinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional 3D printing materials are used, then the printing process is simple, but the mechanical strength of the printed parts is insufficient for commercial applications
Solution Approach 1:
The patent uses a composite powder material consisting of polyalkylene particles (providing structural strength) combined with epoxide-functionalized particles (providing crosslinking capability). This composite approach enables the material to achieve high mechanical strength (3000 MPa or more) while maintaining compatibility with existing 3D printing processes, thus resolving the contradiction between strength and process complexity.
Solution Approach 2:
The patent modifies the chemical parameters of the powder material by incorporating epoxide moieties that can undergo crosslinking reactions. By changing the chemical composition parameters of the powder particles, the material transforms from simple thermoplastic behavior to chemically crosslinked behavior, achieving enhanced mechanical strength without requiring fundamentally new printing equipment.
2Adaptability or versatility
If a limited range of materials is used in 3D printing, then the manufacturing process is straightforward, but the adaptability to different commercial applications is restricted
Solution Approach 1:
The patent develops a universal powder material system that can be applied across multiple commercial sectors (aviation, medical, automotive) by adjusting the formulation parameters. The base polyalkylene particles provide universal structural integrity, while the epoxide functional groups enable crosslinking for enhanced performance in specific applications. This multi-functional material approach maintains ease of manufacture while significantly improving adaptability.
3Reliability
If thermal fusion alone is used to bond powder particles, then the processing is simple, but the resulting parts lack sufficient durability and strength
Solution Approach 1:
The patent merges two bonding mechanisms: thermal fusion (melting of polyalkylene particles) and chemical crosslinking (epoxide hardener reaction). This combination is achieved by incorporating both thermal-sensitive particles and crosslinking agents in the same powder formulation, allowing both mechanisms to operate simultaneously during the printing process. The synergistic effect provides superior durability and strength compared to thermal fusion alone, while maintaining process integration.
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 solution enables the production of 3D printed articles with mechanical strengths of 3,000 MPa or more, offering both thermal fusion and chemical crosslinking, thereby enhancing the material's durability and suitability for commercial applications.
Implementation Method 1
a radiation absorber that absorbs electromagnetic energy and converts the electromagnetic energy to heat
Implementation Method 2
selectively jetting a hardener onto the individual build material layers to cause epoxide moieties to open and become crosslinked
Data Source
AI summary
A 3D printing kit can include a powder bed material comprising from about 80 wt % to 100 wt % polymer particles, a fusing agent to selectively apply to the powder bed material, and a hardener to selectively apply to the powder bed material. The polymeric particles can include a polyalkylene backbone with both ethylene and propylene polymerized monomeric units with from 2 mol % to 15 mol % of the polymerized monomeric units include a grafted side chain having an epoxide moiety. The fusing agent can include water and a radiation absorber that absorbs electromagnetic energy and converts the electromagnetic energy to heat. The hardener can be present in the fusing agent or can be included in a hardening agent that is separate from the fusing agent.