Flame-Retardant Polyamide 3D Printing Using a DOPO Fusing Agent

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing three-dimensional printing technologies lack effective flame retardancy, particularly in polyamide-based materials, which are prone to ignition and flame spread, posing safety risks in rapid prototyping and manufacturing.

Innovation Solution

Incorporation of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) as a flame retardant in the fusing agent and build material, along with a radiation absorber, to generate heat and form a fused polyamide polymer matrix with controlled flame retardant distribution, enhancing the flame resistance of printed objects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polyamide-based build material is used for three-dimensional printing, then the material exhibits good processability and layer adhesion, but the printed objects are prone to ignition and flame spread

Engineering Contradiction:

ImproveprocessabilityVSAvoidflame retardancy

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates flame retardant additives (such as aluminum hydroxide, magnesium hydroxide, or phosphorus-based compounds) into the polyamide build material to create a composite material that maintains the original polyamide's processability while adding flame retardant properties. This composite approach allows the material to be printed effectively while resisting ignition and flame spread.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters of the polyamide material by incorporating flame retardant additives at specific concentrations. This changes the material's thermal and flammability characteristics without fundamentally altering its printability, allowing it to meet flame retardancy standards while maintaining ease of manufacture.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If flame retardant additives are incorporated into the build material, then the flame retardancy of printed objects is improved, but the material composition becomes more complex

Engineering Contradiction:

Improveflame retardancyVSAvoidmaterial composition

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent selects flame retardant additives that serve multiple functions: they provide flame retardancy, maintain or improve layer adhesion, and preserve the material's printability. This multi-functionality reduces the need for additional separate components or complex formulations, as a single additive system addresses multiple requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If conventional printing materials are used without flame retardants, then the printing process is simple, but the printed objects pose safety risks in rapid prototyping and manufacturing

Engineering Contradiction:

Improveprinting processVSAvoidsafety

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent incorporates flame retardant additives into the build material before the printing process begins. This preliminary incorporation ensures that the flame retardant properties are already present in the material, eliminating the need for post-printing safety treatments or modifications, thus maintaining process simplicity while ensuring safety.

Inventive Principle:

Principle #10Preliminary action

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 integrated flame retardant system significantly improves the flame retardancy of three-dimensional printed objects, enabling them to meet or exceed UL 94 V-0 standards, reducing the risk of ignition and flame spread, and ensuring safety in various applications.

Implementation Method 1

a fusing agent including a radiation absorber to generate heat from absorbed electromagnetic radiation

Methodology Applied

Scientific EffectRadiation absorption and heat generation: Absorption (EM radiation)

Implementation Method 2

The flame retardant can include 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide

Methodology Applied

Scientific EffectFlame retardancy:

Data Source

PatentUS12358217B2Three-dimensional printing with flame retardant

Publication Date: 2025.07.15 PERIDOT PRINT LLC

AI summary

A three-dimensional printing kit can include a build material, a fusing agent, and a flame retardant. The build material can include polyamide particles. The fusing agent can include a radiation absorber to generate heat from absorbed electromagnetic radiation and an aqueous liquid vehicle including water. The flame retardant can include 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide. The flame retardant can be included at from about 5 wt % to about 30 wt % in the fusing agent, at from about 5 wt % to about 30 wt % in a flame retardant agent if present that is separate from the fusing agent, or at from about 5 wt % to about 30 wt % in the fusing agent and from about 5 wt % to about 30 wt % in the flame retardant agent.