Liquid Material for 3D Printing with Controlled Contact Angle
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Solution Overview
Problem
Current methods for producing three-dimensional objects face challenges such as nozzle clogging, limited adhesive material selection, inefficiency, uneven adhesive spreading, low strength, and low density due to volatile solvents, which affect the precision and strength of the final product, especially in metal or ceramic sintered bodies.
Innovation Solution
A liquid material containing a solvent and a cross-linking agent with a dynamic contact angle between 20° to 80° is used to harden a powder material, improving wettability and binding force between powder particles, and including a surfactant to adjust surface tension, which enhances the strength and precision of the three-dimensional object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inkjet supplying of adhesive material is used, then three-dimensional object can be formed, but nozzle clogging occurs and adhesive material selection is limited
Solution Approach 1:
The patent changes the physical and chemical parameters of the liquid material by selecting solvents with specific vapor pressure ranges (1-100 mmHg at 20°C) and controlling viscosity (10-1000 cP), which prevents nozzle clogging while maintaining effective powder particle binding. This parameter optimization resolves the contradiction between ease of manufacture and reliability.
Solution Approach 2:
The patent uses composite liquid materials comprising multiple components: solvent, crosslinking agent, and optional surfactant. This composite formulation expands adhesive material selection beyond traditional adhesives, enabling diverse material choices that prevent clogging while ensuring reliable bonding.
2Strength
If adhesive particles are dissolved by delivering binding material, then powder particles can be bound, but uneven spreading occurs reducing strength and precision
Solution Approach 1:
The patent controls the spreading behavior by adjusting liquid material parameters including viscosity (10-1000 cP), surface tension (through surfactant addition), and solvent composition. These parameter changes ensure uniform spreading across the powder layer, achieving both strong binding and high manufacturing precision.
Solution Approach 2:
The patent introduces surfactant as an intermediary substance that mediates between the liquid material and powder particles. The surfactant improves wetting and spreading uniformity, ensuring even distribution of the binding agent across powder particles, which simultaneously enhances strength and precision.
3Strength
If lowly volatile solvents such as toluene are used, then powder particles can be bound effectively, but safety problems arise and solvent remains in the object reducing strength
Solution Approach 1:
The patent changes the volatility parameter of the solvent by selecting from a range of vapor pressures (1-100 mmHg at 20°C). This allows choosing solvents that evaporate at appropriate rates - not too fast to leave residues, not too slow to cause safety issues or strength reduction. The optimized vapor pressure range resolves the contradiction between effective binding and safety.
Solution Approach 2:
The patent converts the potential harm of solvent residues into a benefit by carefully selecting solvents with controlled volatility. The solvent is designed to evaporate completely at appropriate temperatures, transforming from a potential contaminant into a temporary processing aid that enables effective powder binding during manufacturing but leaves no harmful residues in the final product.
4Strength
If coating resin with large thickness is applied, then powder particles can be bound together, but three-dimensional object precision is reduced and base material density is low
Solution Approach 1:
The patent changes the binding mechanism from relying on thick coating layers to using optimized liquid material parameters (viscosity, surface tension, solvent volatility). This allows achieving strong particle binding with minimal liquid material application, maintaining both strength and precision.
Solution Approach 2:
The patent uses a thin, transient liquid material layer that performs its binding function and then evaporates completely. This disposable-like approach - using minimal liquid material that disappears after serving its purpose - avoids the problems of thick permanent coating layers, maintaining precision while achieving binding.
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 proposed solution enables the production of three-dimensional objects with high strength and density, few voids, and improved precision, addressing the limitations of existing methods by ensuring stable jetting and effective binding of powder particles.
Implementation Method 1
A dynamic contact angle of the liquid material over a film made of the organic material is from 20° to 80°
Implementation Method 2
improving wettability and binding force between powder particles
Implementation Method 3
contains a solvent and a cross-linking agent... used to harden a powder material for forming a three-dimensional object containing an organic material
Implementation Method 4
contains a solvent and a cross-linking agent... harden a powder material
Data Source
AI summary
Provided is a liquid material for forming a three-dimensional object. The liquid material is adapted to harden a powder material for forming a three-dimensional object containing an organic material. The liquid material contains a solvent and a cross-linking agent. A dynamic contact angle of the liquid material over a film made of the organic material is from 20° to 80°.