Filled PAEK Powder for Isotropic and Recyclable 3D Sintering
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Solution Overview
Problem
Existing poly-aryl-ether-ketone (PAEK) powders used in 3D printing exhibit anisotropic mechanical properties and are difficult to recycle due to the alignment of carbon fibers, limiting the incorporation of high fiber content, which affects flowability and mechanical reinforcement.
Innovation Solution
A PAEK-based powder with a filler having a Stokes equivalent spherical diameter of 5 micrometers or less is combined with PAEK through extrusion and grinding to achieve isotropic mechanical properties and improved recyclability, using a process that includes heat treatment to enhance crystallinity and reduce abrasion during grinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fibers are added to PAEK powder to improve mechanical properties, then the modulus of elasticity and tensile strength increase, but the powder exhibits anisotropic mechanical properties and reduced flowability
Solution Approach 1:
The patent changes the particle size parameter of the filler from conventional larger sizes to fine particles with D50 ≤ 5 μm. This parameter change allows the filler to be effectively incorporated into the PAEK matrix without causing fiber alignment during compaction, thereby maintaining isotropic mechanical properties and good flowability while achieving enhanced modulus of elasticity and tensile strength.
Solution Approach 2:
The patent creates a composite material system where fine filler particles (D50 ≤ 5 μm) are incorporated into the PAEK matrix through extrusion. This composite structure allows the filler to be uniformly distributed and effectively bonded to the matrix, providing mechanical reinforcement without the anisotropy problems associated with carbon fiber additions.
2Stability of the object's composition
If carbon fibers are incorporated into PAEK particles to achieve isotropic mechanical properties, then the mechanical reinforcement is improved, but the production cost increases and the process complexity increases
Solution Approach 1:
The patent changes the particle size parameter of the filler to fine particles with D50 ≤ 5 μm, which enables effective incorporation into the PAEK matrix through standard extrusion processes. This parameter change achieves isotropic mechanical properties without requiring complex manufacturing processes or high production costs, as the fine particles can be easily mixed and incorporated using conventional equipment.
3Strength
If high proportion of carbon fibers is used to enhance mechanical properties, then the modulus of elasticity increases, but the powder flowability deteriorates and recyclability becomes difficult
Solution Approach 1:
The patent changes the particle size parameter of the filler to fine particles with D50 ≤ 5 μm, which maintains good powder flowability even at high filler proportions. This parameter change enables the powder to be easily handled, deposited, and recycled through standard 3D printing processes, while still achieving enhanced modulus of elasticity and tensile strength.
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 resulting powder produces 3D objects with superior mechanical properties, including higher modulus of elasticity and tensile strength, comparable to those with carbon fiber reinforcement, while being cost-effective and easily recyclable.
Implementation Method 1
The energy required to sinter the powder particles at various points in the powder layer 50 is then supplied by laser radiation 200 from a laser 20
Implementation Method 2
The powder layer 50, during construction, is heated by infrared radiation 100 to reach a substantially uniform temperature
Implementation Method 3
the extrusion-granulation of said at least one polyaryl ether ketone (PAEK) with said at least one filler to form granules
Implementation Method 4
the grinding of the granules to obtain a powder having a volume-weighted particle size distribution
Implementation Method 5
a process that includes heat treatment to enhance crystallinity
Data Source
Figure 1
AI summary
The invention relates to a powder having a volume-weighted particle size distribution with a median diameter D50 ranging from 40 to 120 microns, comprising at least one polyaryletherketone and at least one filler, wherein: - the at least one polyaryletherketone forms a matrix incorporating, at least in part, the at least one filler, and, - the filler has a distribution of equivalent spherical diameters (based on Stokes law) with a median diameter of less than 50 or equal to 5 micrometres. The invention also relates to a method for manufacturing the powder and to the use thereof in a method for constructing objects layer by layer by sintering caused by electromagnetic radiation.