3D Printing Binder Fluid with Particulate Matter for Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional three-dimensional printing processes face limitations in surface contour resolution and apparent density of printed articles, resulting in a rough surface finish and requiring significant material addition for densification, which can lead to geometrical distortion during sintering or thermomechanical processing.
Innovation Solution
The method involves selectively jet-depositing a binder fluid containing particulate matter smaller than the mean particle size of the build material powder, which fills interparticle interstices, increasing the density and improving surface finish of the printed articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional three-dimensional printing processes are used with standard particle layer thickness, then the printing process is simple and fast, but the surface contour resolution is poor and surface finish is rough
Solution Approach 1:
The binder fluid is segmented into two distinct components: a liquid binder and suspended particulate matter. This segmentation allows the smaller particles to fill interparticle voids between larger build material particles, thereby improving surface contour resolution and surface finish without requiring reduction of the overall particle layer thickness, thus maintaining printing speed while enhancing precision.
Solution Approach 2:
The binder fluid delivers particulate matter with locally optimized properties (smaller particle size) specifically to the regions where interparticle voids need to be filled. This local quality enhancement targets the gaps between larger particles, improving surface finish and contour resolution precisely where needed, without affecting the overall structure or requiring process complexity increases.
2Quantity of substance
If conventional three-dimensional printing processes are used with standard powder packing density, then the printing process is straightforward, but the apparent density of printed parts is low requiring significant material addition for densification
Solution Approach 1:
The particulate matter is preliminarily incorporated into the binder fluid before the binding process. This preliminary action ensures that smaller particles are already positioned to fill interparticle voids during the jet deposition process, achieving higher apparent density in the as-printed part and reducing or eliminating the need for subsequent densification processes such as infiltration or sintering.
3Manufacturing precision
If low density powder beds are used in conventional three-dimensional printing, then the printing process is simple, but significant shrinkage occurs during sintering or thermomechanical processing leading to geometrical distortion
Solution Approach 1:
The build material system becomes a composite structure consisting of larger particles providing structural framework and smaller particulate matter filling the interparticle voids. This composite arrangement increases print density while maintaining structural integrity, thereby reducing shrinkage and geometrical distortion during subsequent sintering or thermomechanical processing.
4Quantity of substance
If infiltration is used to densify low density printed parts, then densification can be achieved, but a significant amount of additional material must be added
Solution Approach 1:
The densification action is performed preliminarily during the printing process itself by incorporating smaller particles into the binder fluid that fill interparticle voids as the binder is deposited. This eliminates the need for subsequent infiltration processes that would require adding significant amounts of additional material, thereby reducing material waste while achieving the desired density.
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 surface finish and contour resolution of three-dimensionally printed articles by increasing their apparent density, reducing the need for additional material and minimizing geometrical distortion during densification processes.
Implementation Method 1
selectively jet-depositing a binder fluid which contains suspended particulate matter
Implementation Method 2
the particles of the fluid act to fill in the interparticle voids between the larger particles
Implementation Method 3
selectively jet-printing a fluid onto that layer to cause selected portions of the particulate layer to bind together
Data Source
Figure 1~2
Figure 3
AI summary
Methods and systems (20) are disclosed for making articles by three-dimensional printing. The methods include three-dimensionally printing articles by selectively jet-depositing a particle-bearing binder fluid (14) upon successive layers (4) of a build material powder (10) such that the particles (16) deposited with the binder fluid (14) increase the apparent density of the as- printed article. The particulate matter (16) of the binder fluid (12) is smaller than the mean particle size of the build material powder (10). Preferably, this jet-deposited particulate matter (16) has a mean particle size that is larger than about 1 to and smaller than or equal to 50 microns. The jet-deposited matter (16) acts to fill in the interparticle interstices of the build material powder (10) thereby simultaneously increasing the density of the printed article and improving its surface roughness and contour resolution, which in turn, improves the surface finish of the final article. The systems (20) include binder fluid handling systems (26) which are adapted to jet a binder fluid (14) containing such particulate matter (16).