Fiber-Reinforced 3D Printing Filament Balancing Strength and Woundability
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Solution Overview
Problem
Current technologies face challenges in producing thermoplastic resin filaments for 3D printing that can be wound up while maintaining suitable mechanical properties after building an object, particularly with fiber-reinforced resins like polyphenylene sulfide, polyetherimide, and polyetheretherketone.
Innovation Solution
A fiber-reinforced thermoplastic resin filament containing a thermoplastic resin, a fibrous reinforcing material with specific length and diameter, and an elastomer, which provides tensile and flexural strengths within specified ranges, enabling the filament to be wound up and exhibit suitable mechanical properties when used in 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber-reinforced resin is used to increase rigidity, then mechanical strength is improved, but the filament becomes difficult to wind up
Solution Approach 1:
The patent applies parameter changes by precisely controlling the fiber length (3-9 mm) and fiber diameter (5-20 μm) to achieve optimal balance between mechanical strength and woundability. Additionally, the elastomer content is controlled at 2-35% by weight to modify the resin's flexibility and enable winding while maintaining reinforcement effectiveness.
Solution Approach 2:
The patent uses composite materials by combining thermoplastic resin with fibrous reinforcing material and elastomer in specific proportions. This tri-component composite structure allows the filament to simultaneously achieve high mechanical strength from the fibers, woundability from the elastomer's flexibility, and proper adhesion from the resin matrix.
2Strength
If fiber length is increased to improve mechanical properties, then strength is enhanced, but the filament becomes harder to process and wind
Solution Approach 1:
The patent applies parameter changes by optimizing the fiber length to a specific range of 3-9 mm. This controlled length is sufficient to provide mechanical reinforcement while being short enough to allow easy mixing, processing, and winding during filament manufacturing and 3D printing operations.
3Ease of operation
If elastomer content is increased to improve woundability, then flexibility is enhanced, but mechanical strength may be compromised
Solution Approach 1:
The patent applies parameter changes by controlling the elastomer content within 2-35% by weight. This optimized range provides sufficient flexibility for winding and handling while maintaining adequate mechanical strength through the balanced composite structure with thermoplastic resin and fibrous reinforcement.
Solution Approach 2:
The patent uses composite materials where the elastomer serves as a flexible component that enables woundability, while the thermoplastic resin and fibrous reinforcing material provide the structural backbone for mechanical strength. The synergistic combination of these three components resolves the contradiction between flexibility and strength.
Data Source
AI summary
The present invention provides a fiber-reinforced resin filament and an object, the fiber-reinforced resin filament containing a thermoplastic resin (A), a fibrous reinforcing material (B) having a fiber length of 3 to 9 mm and a fiber diameter of 5 to 20 μm, and an elastomer (C). The fiber-reinforced resin filament of the present invention provides a thermoplastic resin filament for 3D printing that can be wound up, and an object built by fused deposition modeling using this fiber-reinforced resin filament exhibits suitable mechanical properties. This finding has led to completion of the present invention.