FDM Core-Shell Filament for Heat Dissipation
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Solution Overview
Problem
Current methods for 3D printing of luminaires using fused deposition modeling (FDM) are inadequate for efficiently dissipating large amounts of heat, as they rely on graphite-filled polymers with insufficient thermal conductivity or expensive metal printing techniques.
Innovation Solution
A method utilizing a 3D printable material comprising a core-shell structure, where the core material is a metal with a low melting temperature and the shell material is a thermoplastic with a suitable glass transition or melting temperature, printed using a 3D printer with a nozzle temperature above the melting and glass transition temperatures of both materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If graphite-filled polymers are used for heat sinks, then thermal conductivity is improved compared to standard polymers, but thermal conductivity remains insufficient (around 5 W/m K) for dissipating large amounts of heat
Solution Approach 1:
The patent uses a composite material consisting of a thermoplastic matrix combined with metal particles (such as aluminum, copper, or graphite) to create a printable filament that achieves high thermal conductivity. This composite approach allows the material to reach thermal conductivity values sufficient for heat sinks while maintaining printability through the thermoplastic binder.
2Temperature
If metal printing is used for heat sinks, then thermal conductivity and heat dissipation capability are improved, but manufacturing cost and material cost become too expensive for lighting applications
Solution Approach 1:
The patent creates a composite filament where metal particles are dispersed in a thermoplastic matrix, enabling FDM printing of thermally conductive parts at a fraction of the cost of pure metal printing. The thermoplastic binder makes the material compatible with standard FDM printers and significantly reduces material and processing costs.
Solution Approach 2:
The patent modifies the material composition parameters by combining metal particles with thermoplastic materials in specific ratios, optimizing both thermal conductivity and printability. This parameter adjustment allows standard FDM processing temperatures and settings to be used, avoiding the need for expensive metal printing equipment.
3Temperature
If aluminum sheets or extruded profiles are used for heat sinks, then heat dissipation capability is improved, but delivery time increases due to need to order and store parts in advance
Solution Approach 1:
The patent enables customization of heat sink geometry through digital modeling and additive manufacturing, allowing parts to be produced locally and on-demand rather than ordering standard stock items. This eliminates the need for advance ordering and storage while maintaining effective heat dissipation through optimized geometries.
4Adaptability or versatility
If standard FDM printing is used for 3D printed luminaires, then manufacturing flexibility and on-demand production are improved, but thermal management capability deteriorates due to insufficient heat dissipation
Solution Approach 1:
The patent develops a specialized composite filament combining thermoplastic and metal particles that maintains FDM printability while providing high thermal conductivity. This allows standard FDM printers to produce parts with effective thermal management capabilities, resolving the contradiction between manufacturing flexibility and thermal performance.
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 enables the cost-effective and efficient 3D printing of heat-dissipating items, such as heat sinks, with improved thermal management capabilities compared to existing methods.
Implementation Method 1
The nozzle has a nozzle temperature Tn being equal to or higher than the core melting temperature (Tc) and equal to or higher than each of the at least one of the shell glass transition temperature (Tg) and the shell melting temperature (Ts)
Implementation Method 2
melting the 3D printable material in the nozzle
Implementation Method 3
the 3D printable shell material comprises a thermoplastic material having at least one of a shell glass transition temperature (Tg) and a shell melting temperature (Ts)
Implementation Method 4
the 3D printable core material comprises a metal having a core melting temperature (Tc)
Data Source
AI summary
The present invention relates to a method for producing, by means of fused deposition modelling, a 3D item that has the ability to dissipate relatively large amounts of heat. The method uses a 3D printable material (1) that comprises a 3D printable shell material (3) and a 3D printable core material (2). The 3D item (7) comprises a plurality of layers (6) of a 3D printed material (1′), each layer (6) having a layer shell comprising a 3D printed shell material (3′) and at least partly enclosing a layer core comprising a 3D printed core material (2′). The method comprises the steps of (i) feeding the 3D printable material (1) into a nozzle of a 3D printer, and (ii) layer-wise depositing the 3D printable material (1) to provide the 3D item (7). The 3D printable core material (2) comprises a metal having a core melting temperature, and the 3D printable shell material (3) comprises a thermoplastic material having at least one of a shell glass transition temperature and a shell melting temperature. The nozzle has a nozzle temperature that is equal to or higher than the core melting temperature and equal to or higher than each of the at least one of the shell glass transition temperature and the shell melting temperature.