Laser Sintered Articles Infiltrated with Elastomeric Polymer
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Solution Overview
Problem
Laser sintering (LS) technology produces articles with inadequate strength, hardness, and surface finish due to porosity, limiting their practical applications, and existing infiltration methods alter the dimensions or physical properties of the articles.
Innovation Solution
A method using a liquid infiltrant comprising an elastomeric polymeric material, such as natural latex in a suitable vehicle, applied to the article to fill voids and improve strength and esthetics without altering dimensions or flexibility, involving multiple applications and drying steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If infiltration is performed to improve strength and surface finish, then physical and esthetic properties are improved, but dimensions of the article are altered
Solution Approach 1:
The patent applies parameter changes by controlling the viscosity of the infiltrant composition and regulating the temperature and time parameters during infiltration. By adjusting these parameters, the infiltrant fills pores and voids to improve strength and surface finish while minimizing dimensional alterations of the laser-sintered article.
2Strength
If infiltration is performed to improve hardness and abrasion resistance, then physical properties are improved, but flexibility of flexible articles is altered
Solution Approach 1:
The patent uses parameter changes by carefully controlling the viscosity of the infiltrant and the infiltration conditions (temperature, time) to achieve the desired balance between hardness and flexibility. The infiltrant composition is designed to penetrate and strengthen the article without excessive rigidification, thereby maintaining flexibility while improving hardness and abrasion resistance.
3Adaptability or versatility
If laser sintering is used to manufacture articles, then complex three-dimensional shapes can be produced, but the articles have inadequate strength and surface finish due to porosity
Solution Approach 1:
The patent applies composite materials by combining the laser-sintered particulate material with an infiltrant composition that penetrates the porous structure. The infiltrant fills the voids between particles, creating a composite structure that retains the complex three-dimensional geometry while significantly improving strength, hardness, and surface finish.
4Quantity of substance
If existing infiltration methods are used, then porosity is reduced, but the physical properties and dimensions of the article are altered
Solution Approach 1:
The patent applies parameter changes by precisely controlling the viscosity of the infiltrant composition and the infiltration process parameters (temperature, time, atmosphere). These controlled parameter changes enable effective pore filling to reduce porosity while minimizing alterations to the original physical properties and dimensions of the laser-sintered article.
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 method enhances the strength, durability, and esthetics of LS-produced articles while maintaining their original dimensions and flexibility, resulting in improved mechanical properties and a smooth, nonporous surface.
Implementation Method 1
A laser beam then traces a predetermined cross section of an article on the layer of heated particulate material in the build surface, thus forming a solid layer
Implementation Method 2
A method using a liquid infiltrant comprising an elastomeric polymeric material, such as natural latex in a suitable vehicle, applied to the article to fill voids and improve strength and esthetics
Implementation Method 3
involving multiple applications and drying steps
Data Source
AI summary
A composition and method of infiltrating an article of manufacture prepared by a laser sintering process is disclosed. The infiltration process maintains the dimensions and flexibility of the article, increases the strength of the article, and improves the physic& and esthetic properties of the article.