Semi-Crystalline FDM Build Plate Heating for Layer Adhesion
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Solution Overview
Problem
Existing 3D printing methods using semi-crystalline polymers often result in the printed items collapsing or detaching from the receiver item during the printing process, leading to incomplete or inferior 3D printed objects.
Innovation Solution
A method for 3D printing using semi-crystalline polymers that involves controlling the nozzle temperature, receiver item temperature, and layer-wise cooling to maintain adhesion and structural integrity, including sub-stages of depositing, cooling, and selecting appropriate temperatures to ensure the semi-crystalline polymer remains partially melted and adhered to the receiver item.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If semi-crystalline polymer is used for 3D printing, then material strength and structural integrity are improved, but the printed item collapses or detaches from the receiver item during printing
Solution Approach 1:
The receiver item temperature is dynamically adjusted during the printing process. The temperature is raised above the melting temperature of the semi-crystalline polymer during material deposition to ensure adhesion, then lowered below the melting temperature between layers to maintain structural integrity and prevent collapse
Solution Approach 2:
The temperature parameter of the receiver item is changed at different stages of the printing process. By cycling the temperature above and below the polymer's melting point, the system achieves both good adhesion during deposition and structural stability during cooling
2Reliability
If receiver item temperature is raised above melting temperature to improve adhesion, then material adheres better, but printed layers collapse due to loss of rigidity
Solution Approach 1:
The receiver item temperature is periodically cycled between above and below the melting temperature of the semi-crystalline polymer. This periodic temperature variation enables alternating phases of adhesion (when hot) and structural stabilization (when cool), resolving the contradiction between these two requirements
3Stability of the object's composition
If cooling is applied to maintain structural integrity, then layer stability is improved, but adhesion to receiver item deteriorates
Solution Approach 1:
The printing process is segmented into distinct phases: a deposition phase where temperature is maintained above melting point for adhesion, and a cooling phase where temperature is lowered below melting point for structural stability. This temporal segmentation allows each phase to optimize for its specific requirement
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 prevents 3D printed items from collapsing and detaching, ensuring better structural maintenance and adhesion to the receiver item by tuning printing conditions, particularly temperatures, and enhancing the printed material's viscosity and rigidity.
Implementation Method 1
the printable material comprises a semi-crystalline polymer... the 3D printable material has (i) a melting temperature range, ranging from a first melting temperature TM1 to a second melting temperature TM2
Implementation Method 2
the 3D printable material has (ii) a crystallization temperature range, ranging from a second crystallization temperature TC2 to a first crystallization temperature TC1
Implementation Method 3
depositing 3D printable material on the receiver item having a first receiver item temperature TB1... TB1≥TC1, especially, TB1≥TM1. In more specific embodiments, TB1≥TM2
Implementation Method 4
the method comprises during a second sub-stage of the 3D printing stage: (actively) cooling n12 first layers of the n1 first layers
Data Source
AI summary
A method for producing a 3D item (1) by means of fused deposition modelling of 3D printed material (202) on a receiver item (550), wherein the 3D item (1) comprises a plurality of layers (322) of 3D printed material (202); wherein: (a) the printable material (201) comprises a semi-crystalline polymer; (b) the 3D printable material (201) has (i) a melting temperature range, ranging from a first melting temperature TM1 to a second melting temperature TM2, wherein TM2>TM1, and (ii) a crystallization temperature range, ranging from a second crystallization temperature Tc2 to a first crystallization temperature Tci, wherein TC2>TC1; (c) the 3D printing stage comprises guiding the 3D printable material (201) through a printer nozzle (502) at a nozzle temperature TN; wherein TN>TM2; (d) the method comprises during a first sub-stage of the 3D printing stage: depositing 3D printable material (201) on the receiver item (550) having a first receiver item temperature TB1, to provide n1 first layers (1322) on the receiver item (550); wherein TB1>TM2; (e) the method comprises during a second sub-stage of the 3D printing stage: cooling n12 first layers of the n1 first layers (1322) and selecting a second receiver item temperature TB2 of the receiver item (550), wherein TN2<TB1; and (f) the method comprises during a third sub-stage of the 3D printing stage: depositing 3D printable material (201) on the previously deposited n1 first layers (1322), to provide n2 second layers (2322) thereon.