FDM Core-Shell Printing With Thermally Conductive Wire Cores
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D printing technologies, particularly FDM, struggle to produce thermally conductive heatsinks for luminaires due to the limited thermal conductivity of graphite-filled polymers and the high cost and logistical challenges of using metals, leading to increased costs and delivery delays.
Innovation Solution
A method involving fused deposition modeling (FDM) that combines a thermoplastic shell material with a core of thermally conductive wires, where the core component is fed through or adjacent to the nozzle, using materials like tin, copper, or graphite wires, and a flexible mantle to enhance thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If graphite filled polymers are used for heatsinks, then thermal conductivity is improved, but thermal conductivity remains insufficient (around 5W/m·K)
Solution Approach 1:
The invention uses a composite filament structure with a thermoplastic shell material and a core component containing multiple thermally conductive wires (copper, aluminum, or graphite) surrounded by a flexible mantle. This composite structure combines the structural benefits of polymers with the high thermal conductivity of metal wires, achieving thermal conductivity significantly higher than graphite-filled polymers alone.
2Temperature
If metal printing is used for heatsinks, then thermal conductivity is improved, but cost and delivery time worsen
Solution Approach 1:
The invention merges FDM 3D printing technology with a specially designed core-shell filament structure to achieve metal-like thermal conductivity in a cost-effective manner. The thermoplastic shell material provides structural integrity while the embedded thermally conductive wires provide high thermal conductivity, eliminating the need for expensive metal printing processes.
3Temperature
If metal printing is used for heatsinks, then thermal conductivity is improved, but delivery time worsens due to pre-ordering and storage requirements
Solution Approach 1:
The invention enables on-demand manufacturing of heatsinks using standard FDM 3D printers with the specialized core-shell filament. This eliminates the need for pre-ordering and storing metal components, allowing heatsinks to be printed locally and immediately when needed, significantly reducing delivery time and supply chain dependencies.
4Ease of manufacture
If thermoplastic shell material is heated to melting point for extrusion, then 3D printing is enabled, but thermal stress on core wires worsens
Solution Approach 1:
The invention uses a flexible mantle material surrounding the thermally conductive wires in the core component. This flexible mantle protects the wires from excessive thermal stress during the extrusion process while allowing the shell material to be heated to its melting point for proper extrusion and bonding. The flexible mantle acts as a thermal buffer and mechanical protector.
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 allows for the cost-effective and efficient production of thermally conductive 3D items with improved heat dissipation, maintaining structural integrity and reducing mechanical stress on the wires.
Implementation Method 1
a shell component comprising a thermoplastic 3D printable shell material having a shell melting temperature Tms and/or a shell glass transition temperature Tgs
Implementation Method 2
a shell component comprising a thermoplastic 3D printable shell material having a shell melting temperature Tms and/or a shell glass transition temperature Tgs
Implementation Method 3
a core component comprising a plurality of N thermally conductive wires
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to a method for manufacturing a 3D item (100) by means of fused deposition modelling (FDM), the method comprising the steps of: a) providing a shell component (5') comprising a thermoplastic 3D printable shell material having a shell melting temperature (Tms) and/or a shell glass transition temperature (Tgs); b) providing a core component (2') comprising a plurality of thermally conductive wires (3) and a flexible mantle (4) enclosing the plurality of thermally conductive wires (3); c) feeding the shell component (5) into a nozzle (6) of a 3D printer, the nozzle (6) having a nozzle temperature (Tn) being equal to or greater than the shell melting temperature (Tms) and/or the shell glass transition temperature (Tgs); d) a layer-wise depositing of the 3D printable shell material and the core component (2) to provide the 3D item (100) comprising a core-shell layer (100') of 3D printed material, wherein the 3D printed material comprises a core (102) comprising the core component, and shell (105) comprising 3D printed shell material, wherein the shell (105) at least partly encloses the core (102).