Glass Filament Additive Manufacturing with Polyimide Coating

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Solution Overview

Problem

Existing glass 3D printing methods face challenges such as nozzle damage from molten glass, time-consuming post-processing, limited thickness and accuracy, and risks from chemical coatings, including self-sustained combustion and toxic by-products, which hinder the production of high-quality three-dimensional glass components.

Innovation Solution

A method using glass filaments with a polyimide-based flame retardant or self-extinguishing protective film, applied in a range of 1 μm to 50 μm thickness, which is removed during the printing process using a laser-based heating source, ensuring the coating is flame retardant and non-toxic, and allowing for longer filament lengths and improved mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a protective coating is applied to glass filaments to prevent breakage during handling, then mechanical strength is improved, but the coating may self-combust and produce toxic by-products during the printing process

Engineering Contradiction:

Improvemechanical strength of filamentVSAvoidtoxic by-products and self-combustion

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters of the protective coating by incorporating flame retardant additives (such as aluminum hydroxide, magnesium hydroxide, or phosphorus-based compounds) into the coating formulation. This modifies the thermal and chemical properties of the coating to prevent self-combustion and toxic emissions while preserving mechanical protection during handling.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite protective coating structure combining polymer matrix materials with flame retardant inorganic fillers (metal hydroxides, phosphates) and surface treatment agents. This composite structure provides both mechanical strength enhancement and fire safety, eliminating the harmful effects of conventional organic coatings during the high-temperature printing process.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional organic coatings are used on glass filaments, then mechanical protection is provided, but combustion occurs during printing releasing toxic substances

Engineering Contradiction:

Improvemechanical protectionVSAvoidcombustion and toxic emissions

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potential harmful effect of heat exposure during printing into a beneficial outcome by designing a coating that undergoes controlled thermal decomposition of flame retardant additives. This decomposition releases water vapor and non-toxic gases that suppress combustion, transform the thermal stress from harmful to protective, and create a char layer that further prevents burning while maintaining mechanical integrity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach enables the direct manufacturing of fully or near-fully dense glass components with improved printing accuracy and safety, avoiding toxic by-products and reducing filament breakage, while maintaining the mechanical integrity of the glass filaments.

Implementation Method 1

a laser-based heating source, wherein the heating source removes the protective film

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

a laser-based heating source, wherein the heating source removes the protective film

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20240368018A1Method and apparatus for additive manufacturing of glass

Publication Date: 2024.11.07 NOBULA3D AB

AI summary

This relates to an additive manufacturing method for producing a three-dimensional component made of glass, the method including the steps of: feeding continuously a glass filament having a flame retardant or self-extinguishing protective film applied to the surface thereof, from a filament feeding nozzle to a heating source for removing the flame retardant or self-extinguishing protective film and softening the glass fiber, applying the softened glass filament to a surface of a substrate or object, wherein the flame retardant or self-extinguishing protective film is made of polyimide-based material having a thickness in the range of 1 μm to 50 μm, wherein the fed glass filament length is less than 5 millimeters. The invention is also related to a glass filament and the use of the same.