FDM Core-Shell Filament for Wood-Like 3D Printing
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Solution Overview
Problem
Existing 3D printing techniques, such as polyjet, struggle with producing stable and thermally conductive materials suitable for injection molding applications, and FDM lacks the ability to replicate the look and feel of wood effectively.
Innovation Solution
A method using fused deposition modeling (FDM) to create 3D printed items with a core-shell structure, where the core material can consist of metal particles or a metal wire, and the shell material can consist of wood particles or inorganic materials like glass or ceramic particles, to achieve a wood-like appearance and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polyjet technique is used for 3D printing molds, then smooth surfaces are produced, but the photo curable materials are unstable and have low thermal conductivity
Solution Approach 1:
The patent uses composite materials consisting of thermoplastic polymer matrix combined with wood particles, metal particles, or ceramic particles. This composite approach allows achieving both smooth surfaces through proper formulation and printing parameters, and improved material stability through the inherent properties of thermoplastics and reinforcing particles, while also enhancing thermal conductivity.
2Productivity
If FDM technique is used for 3D printing, then printing speed and cost are improved, but the ability to replicate wood look and feel is insufficient
Solution Approach 1:
The patent incorporates wood particles, metal particles, or ceramic particles within thermoplastic polymer matrices in FDM printing. This composite approach enables the material to replicate wood grain patterns, textures, and visual characteristics while maintaining the fast printing speeds and cost-effectiveness of FDM technology.
Solution Approach 2:
The patent uses multi-material or multi-color FDM printing capabilities to create local variations in material composition, allowing different regions of the printed object to have distinct wood-like appearances, grain patterns, and textures that match specific wood species or design requirements.
3Manufacturing precision
If wood material is used for constructing 3D wood structures, then natural appearance is achieved, but formaldehyde and synthetic resins are present in the composition
Solution Approach 1:
The patent changes the chemical composition parameters by using thermoplastic polymers as the base material instead of traditional wood-based composites containing formaldehyde. The incorporation of natural wood particles, metal particles, or ceramic particles within safe polymer matrices achieves wood appearance without harmful emissions.
Solution Approach 2:
The patent uses biodegradable or environmentally friendly thermoplastic polymers that can replace traditional wood products in certain applications, reducing the need for formaldehyde-treated wood and synthetic resins while maintaining aesthetic and functional properties.
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 allows for the creation of 3D printed items that visually and tactually resemble wood, while also offering improved safety and durability due to the use of metal and inorganic materials, and reduces the need for new polymeric materials.
Implementation Method 1
FDM works on an 'additive' principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. Possibly, (for thermoplastics for example) the filament is melted and extruded before being laid down.
Implementation Method 2
the 3D printable core material may comprise one or more of metal particles and a metal wire; further, in specific embodiments the 3D printable shell material may comprise wood particles. Alternatively or additionally, the 3D printable core material may comprise wood particles; further, in specific embodiments the 3D printable shell material may comprise non-wood particles, such as inorganic material particles, especially selected from the group of glass particles and ceramic particles.
Data Source
AI summary
The invention provides a method for producing a 3D printed item (1) by means of fused deposition modelling, wherein the 3D printed item (1) comprises a plurality of layers (322) of 3D printed material (202), comprising a layer part (1322) with a 3D printed shell material (1302) at least partially surrounding a 3D printed core material (1202), wherein the method comprises layer-wise depositing a 3D printable material (201) comprising a 3D printable core material (1201) and a 3D printable shell material (1301), and wherein:—the 3D printable core material (1201) comprises one or more of metal particles (260) and a metal wire (270), and the 3D printable shell material (1301) comprises wood particles (250), or—the 3D printable core material (1201) comprises wood particles (250), and the 3D printable shell material (1301) comprises inorganic material particles (280) selected from the group of glass particles and ceramic particles.