Multi-Component Micro-Pellets for Additive Manufacturing

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Solution Overview

Problem

Conventional powder-based materials used in additive manufacturing are expensive and limited in the types of polymers they can work with, restricting the variety of materials that can be used in powder-based additive manufacturing processes.

Innovation Solution

The development of multi-component micro-pellets formed from multiple polymer fibers, which are then size-reduced to create powders with controlled microstructure and properties, allowing for a wider range of polymer materials to be used in additive manufacturing processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional powder-based materials are used in additive manufacturing, then the manufacturing process is established, but the variety of polymeric materials is limited and costs are high

Engineering Contradiction:

Improvevariety of polymeric materialsVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention segments polymer materials into multi-component micro-pellets with distinct core and shell portions, each containing different polymer materials. This segmentation enables independent optimization of each component's properties while maintaining overall material functionality in additive manufacturing processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates composite powder-based materials by combining multiple polymer materials within single micro-pellet structures. The core-shell configuration allows integration of different polymer types (e.g., thermoplastics, thermosets, elastomers) to achieve enhanced versatility and performance characteristics.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If multi-component micro-pellets are formed from multiple polymer fibers, then the variety of materials increases, but the manufacturing process complexity increases

Engineering Contradiction:

Improvevariety of polymeric materialsVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention performs preliminary formation of multi-component fibers from multiple polymer feeds before the actual additive manufacturing process. This pre-preparation of structured fibers with core-shell configurations simplifies the subsequent powder processing and 3D printing operations by providing pre-configured material architectures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention controls the morphology and dimensions of micro-pellets by adjusting fiber diameter and cutting parameters. By optimizing these physical parameters, the invention achieves controlled microstructure in the final powder materials without requiring complex processing equipment or procedures.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If the size and distribution of micro-pellets are controlled, then the quality of 3D objects improves, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvequality of 3D objectsVSAvoidcontrol of micro-pellet size and distribution

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The invention replaces complex mechanical sorting and separation systems with a simpler approach using controlled fiber cutting and aggregation. The micro-pellet dimensions are determined by the fiber diameter and cutting parameters rather than requiring precise mechanical sorting, thereby reducing measurement and control requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention achieves homogeneous size distribution of micro-pellets by controlling the fiber formation and cutting processes to produce uniform dimensions. This homogeneity is achieved through process control rather than post-processing sorting, simplifying the manufacturing precision requirements while maintaining high 3D object quality.

Inventive Principle:

Principle #33Homogeneity

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 increases the variety of polymeric materials that can be used, improves the quality and mechanical properties of 3D objects by controlling the size and distribution of micro-pellets, and enhances the temperature window of the selective laser sintering process, leading to more forgiving and efficient additive manufacturing processes.

Implementation Method 1

A laser beam is raster scanned across the surface of a layer of powder, turning on and off to selectively sinter or fuse the polymer powder particles

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

selectively sinter or fuse the polymer powder particles into a shape defined by a computer

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

selected exposure to electromagnetic radiation, or electron beam

Methodology Applied

Scientific EffectElectron beam heating: Electron Beam

Data Source

PatentUS10343303B2Materials for powder-based additive manufacturing processes

Publication Date: 2019.07.09 EVONIK OPERATIONS GMBH

AI summary

A multi-component micro-pellet useful as a consumable material for making objects by powder based additive manufacturing is disclosed. A method of making said micro-pellet is also disclosed. An object made by using said micro-pellets is also disclosed.