Fused Filament Deposition of High-Load Ceramic and Metal Composites
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Solution Overview
Problem
Conventional fused deposition modeling techniques face limitations in achieving homogeneous dispersion of inorganic particles within thermoplastic polymers, leading to thermal degradation, reduced printing accuracy, and compromised mechanical integrity, especially when dealing with high inorganic particle loads or 100% inorganic materials.
Innovation Solution
A method involving the preparation of a stable suspension of inorganic particles, solvent removal, redispersion in a polymer solution, drying without temperature, determination of the extrusion window, and extrusion within specific thermal parameters to produce filaments suitable for 3D printing, ensuring homogeneous dispersion and optimal thermal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional fused mixing process is used to mix inorganic particles with thermoplastic polymer, then the mixing can be performed at relatively low temperature (250°C-270°C), but the high viscosity of the mixture (> 100 Pa·s) limits the amount of inorganic particles and their dispersion in the thermoplastic matrix
Solution Approach 1:
The patent changes the temperature parameter from conventional mixing (250°C-270°C) to elevated temperature (above 270°C, up to decomposition temperature) to reduce mixture viscosity and enable higher inorganic particle loads with improved dispersion. It also changes the processing approach by using a single-step extrusion process with carefully controlled residence time to prevent degradation while achieving homogeneous mixing at high temperatures.
Solution Approach 2:
The patent develops composite material formulations with high inorganic particle content (exceeding conventional limits) by optimizing the polymer-inorganic particle interface through surface treatment and controlled processing, creating new composite material systems that maintain stability and homogeneity despite high filler loads.
2Ease of manufacture
If the amount of thermoplastic polymer is increased to satisfactorily print 100% inorganic pieces, then printing can be performed, but the mechanical consistency and integrity of the piece is compromised during shrinkage processes
Solution Approach 1:
The patent optimizes the thermoplastic polymer content to the minimum necessary for printability while using elevated processing temperatures and controlled extrusion parameters to ensure homogeneous dispersion and proper bonding. This reduces the polymer matrix volume that would otherwise cause shrinkage and mechanical integrity issues during sintering.
Solution Approach 2:
The patent performs preliminary surface treatment of inorganic particles and optimized mixing at elevated temperatures before extrusion to ensure proper particle-polymer interface and homogeneous distribution, which preconditions the composite for minimal shrinkage and maintained mechanical integrity during subsequent sintering processes.
3Productivity
If inorganic particles are mixed with fused thermoplastic polymer in conventional fused mixing, then the mixture can be processed, but the high viscosity limits both the amount of inorganic particles and their dispersion
Solution Approach 1:
The patent uses elevated temperature processing (above 270°C) to dramatically reduce mixture viscosity, enabling both high productivity through efficient mixing and high manufacturing precision through excellent particle dispersion and homogeneous material flow during extrusion and printing.
Solution Approach 2:
The patent replaces conventional mechanical mixing at low temperature with thermal processing at elevated temperature, using heat as the primary mechanism to reduce viscosity and enable both efficient processing and precise printing with high inorganic particle content.
4Stability of the object's composition
If conventional double spindle extruder mixing is used, then homogeneous mixture can be achieved, but thermal degradation of material and/or final mixture may occur
Solution Approach 1:
The patent replaces conventional mechanical mixing with a single-step extrusion process that uses controlled thermal energy at elevated temperatures with optimized residence time to achieve homogeneous mixing without the prolonged mechanical shearing and repeated cooling-heating cycles that cause thermal degradation in conventional processes.
Solution Approach 2:
The patent implements a continuous extrusion process where mixing, heating, and extrusion occur in a single continuous operation without interruption or repeated cycles, maintaining the material in a controlled state and preventing thermal degradation while achieving homogeneous dispersion of inorganic particles.
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 method enables the production of composite, ceramic, or metallic pieces with high inorganic loads, maintaining mechanical and functional properties, and achieving consistent densities, thereby improving printing accuracy and final piece integrity.
Implementation Method 1
the thermoplastic polymer is fused, exceeding in all cases its glass transition temperature (Tg) and melting temperature (Tm)
Implementation Method 2
the thermoplastic polymer is fused, exceeding in all cases its glass transition temperature (Tg) and melting temperature (Tm)
Implementation Method 3
the dispersion of inorganic particles in the polymer directly affects the homogeneity of the extruded filaments
Implementation Method 4
the amount of thermoplastic polymer to satisfactorily print is usually so high (> 30% by volume) that it affects the mechanical consistency and integrity of the piece, during the shrinkage processes generated during the thermal sintering treatment that consolidate the inorganic structure
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3B
AI summary
The present invention relates to a method for obtaining a composite material piece or a ceramic and/or metal piece by fused filament deposition modeling. The present invention is framed in the area of materials science and is therefore of interest for industries that manufacture composite materials composed of a polymer, ceramic and metal matrix for applications in aeronautics, production of biomaterials, energy generation/storage devices and refractory materials used in severe service conditions.