In-situ Crosslinked Polyamide Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing of polyamide objects faces challenges in achieving desired physical properties due to limitations in melt flow rates and consolidation of highly crosslinked polyamides, which affects heat resistance and abrasion resistance.

Innovation Solution

The compositions and methods involve in situ crosslinking of unsaturated polyamides during additive manufacturing by using initiator-doped particles, allowing for improved consolidation and properties through controlled crosslinking during the process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polyamide is used in additive manufacturing, then flow properties and sintering window are improved, but heat resistance and abrasion resistance are insufficient

Engineering Contradiction:

Improveflow propertiesVSAvoidheat resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the chemical structure of polyamide by introducing unsaturated bonds (C=C double bonds) into the polymer chain. This structural modification allows the polyamide to undergo crosslinking reactions during additive manufacturing, transforming it from a thermoplastic to a crosslinked network structure that provides both good flow properties during processing and enhanced heat resistance in the final product.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite system by combining unsaturated polyamide with crosslinking agents or initiators. This composite approach allows the material to exhibit thermoplastic behavior during additive manufacturing (due to the polyamide matrix) while simultaneously developing crosslinked network structures that provide improved heat resistance and abrasion resistance in the consolidated object.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If polyamide is used in additive manufacturing, then cost is reduced, but consolidation and physical properties are insufficient

Engineering Contradiction:

ImprovecostVSAvoidconsolidation

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent modifies the physical and chemical parameters of polyamide by introducing unsaturation, which enables crosslinking during the consolidation phase of additive manufacturing. This parameter change transforms the material from a simple thermoplastic with limited consolidation capability to a crosslinking system that achieves superior consolidation and mechanical properties while maintaining cost-effectiveness.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If crosslinking is performed during additive manufacturing, then heat resistance and abrasion resistance are improved, but melt flow rate and consolidation become challenging

Engineering Contradiction:

Improveheat resistanceVSAvoidmelt flow rate

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent incorporates crosslinking agents or initiators into the polyamide material before the additive manufacturing process. This preliminary action ensures that the crosslinking capability is pre-built into the material, allowing crosslinking to occur during or after consolidation without requiring separate post-processing steps, thus maintaining both good melt flow during printing and achieving crosslinked properties in the final object.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs a two-stage process where polyamide is first deposited in a thermoplastic state with good flow properties, then crosslinking is activated subsequently through heat treatment or chemical initiation. This periodic action separates the deposition phase (requiring good melt flow) from the crosslinking phase (providing heat resistance), allowing each stage to optimize for its specific requirements.

Inventive Principle:

Principle #19Periodic 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

This approach enhances the heat resistance and abrasion resistance of the resulting polyamide objects by enabling effective crosslinking within the additive manufacturing process, addressing the limitations of melt flow rates and consolidation.

Implementation Method 1

heating at least a portion of the particles to promote consolidation thereof and crosslinking of the unsaturated polyamide

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 2

crosslinking of the unsaturated polyamide, thereby forming a consolidated body comprising a crosslinked polyamide

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS12043755B2Compositions, methods, and articles relating to in-situ crosslinking of polyamides during additive manufacturing

Publication Date: 2024.07.23 XEROX CORP

AI summary

Particles may be produced that comprise an unsaturated polyamide and an initiator. Said particles may be used in additive manufacturing methods that comprise: depositing the particles optionally in combination with other thermoplastic polymer particles upon a surface; and once deposited, heating at least a portion of the particles to promote consolidation thereof and crosslinking of the unsaturated polyamide, thereby forming a consolidated body comprising a crosslinked polyamide.