Lignosulfate 3D Printing Soluble Core Demolding
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Solution Overview
Problem
Current 3D printing technologies face challenges in producing complex geometries and laminated parts, particularly in cold casting and laminating processes, as existing methods are either insufficient or damage the mold when trying to remove inner structures or undercuts.
Innovation Solution
A 3D printing material system using a mixture of inorganic or organic particle materials with a lignin-containing printing liquid, which allows for easy demolding with a solvent, enabling the production of moldings that can be reused and are cost-effective, environmentally friendly, and suitable for various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical removal of insert cores is used, then inner structures can be removed, but the final mold is damaged
Solution Approach 1:
The patent extracts the harmful mechanical removal step by introducing a soluble component that dissolves in a solvent, allowing inner structures to be removed chemically rather than mechanically, thus preserving mold integrity while achieving the goal of removing insert cores
Solution Approach 2:
The soluble component acts as an intermediary substance between the insert core and the final product. It provides temporary structural support during manufacturing but can be easily removed via solvent, serving as a mediator that facilitates core removal without damaging the mold
2Ease of operation
If mechanical destruction of the mold is used, then laminates can be exposed, but almost closed structures cannot be produced and the laminate is damaged
Solution Approach 1:
The patent replaces the mechanical destruction system with a chemical dissolution system. Instead of mechanically breaking apart the mold to expose laminates, the soluble component dissolves in a solvent, allowing clean extraction of laminates from complex closed structures without damage
3Object-affected harmful factors
If inorganic binders are used, then the mold is environmentally friendly, but high energies must be applied to prevent weakening during casting
Solution Approach 1:
The patent changes the chemical parameters of the binder system by using organic binders with controlled solubility characteristics. This allows the mold to maintain environmental friendliness while reducing energy requirements, as the soluble component dissolves at moderate temperatures rather than requiring high energy input
4Strength
If cold resin bonding is used, then the mold strength is maintained, but the surface must be coated and sealed and a release agent must be applied
Solution Approach 1:
The patent extracts the unnecessary surface preparation steps by using a soluble component that allows direct demolding through dissolution. The surface coating, sealing, and release agent application steps are eliminated because the mold can be removed simply by dissolving the soluble component
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 solution enables the production of moldings with desired properties, allowing for the creation of complex geometries and laminated parts without damaging the mold, and facilitates easy removal and reuse of the moldings, enhancing the cost-effectiveness and environmental sustainability of the 3D printing process.
Implementation Method 1
a thin layer of particle material is deposited on a platform and has a liquid selectively printed thereon by means of a print head. In the area printed with the liquid, the particles become bonded and the area solidifies under the influence of the liquid
Implementation Method 2
the particles become bonded and the area solidifies under the influence of the liquid and, if necessary, an additional hardener
Data Source
AI summary
The present invention relates to a material system for 3D printing, to a 3D printing process using a lignin-containing component or derivatives thereof or modified lignins, to soluble moldings that are produced by a powder-based additive layer manufacturing process and to the use of the moldings.