Microstructured Calcium-Salt Composite Powder for Selective Laser Sintering
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Solution Overview
Problem
Existing calcium salt-containing composite powders for selective laser sintering have poor pourability, leading to unsatisfactory surface quality, component density, and dimensional stability, and are prone to thermal degradation, which complicates their use in medical applications where solvent-free and biocompatible materials are required.
Innovation Solution
A composite powder with microstructured particles, where large particles (10 μm to 10 mm) are combined with small calcium salt particles (0.01 μm to 1.0 mm), with a specific particle size distribution and calcium salt content, using polymers like polylactides and calcium carbonate, to enhance pourability, surface quality, and dimensional stability, and prevent thermal degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite particles with small calcium salt particles arranged on large polymer particles are used, then material properties for medical applications are improved, but pourability deteriorates
Solution Approach 1:
The patent changes the particle size parameters by specifying that the large particles have an average diameter of 10-1000 μm and the small calcium salt particles have an average diameter of 0.1-10 μm, with the small particles comprising 10-90 wt% of the composite. This specific parameter range optimization resolves the contradiction by achieving both good material properties and acceptable pourability without requiring pouring aids.
2Ease of operation
If pouring aids are added to improve pourability, then flow properties are improved, but biological compatibility and biodegradability deteriorate
Solution Approach 1:
The patent extracts and eliminates the need for pouring aids by optimizing the intrinsic particle size distribution of the composite material itself. By carefully controlling the size ratio and composition of large polymer particles and small calcium salt particles, the material achieves self-flow properties without requiring any additional pouring aid substances that would compromise biological compatibility.
3Ease of manufacture
If ground composite particles are used for laser sintering, then production is simplified, but surface quality and component density deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-forming the composite particles with optimized size distribution and morphology before the laser sintering process. The large polymer particles serve as cores with small calcium salt particles pre-arranged on their surfaces, creating a structured composite that maintains its integrity during handling and sintering, thereby achieving good surface quality and density without requiring post-processing ground particles.
4Adaptability or versatility
If conventional composite particles are used, then material availability is improved, but shrinkage behavior and dimensional stability deteriorate
Solution Approach 1:
The patent employs composite materials by combining large polymer particles (10-1000 μm) with small calcium salt particles (0.1-10 μm) in a specific configuration where the small particles are arranged on the surfaces of the large particles. This composite structure, with the inorganic calcium salt shells on organic polymer cores, creates a material that maintains dimensional stability and controlled shrinkage behavior during laser sintering while remaining available for production.
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 composite powder improves pourability, surface quality, and component density, achieving high-quality components with excellent mechanical and biological compatibility, and allows for controlled resorption kinetics and mechanical properties, suitable for medical implants.
Implementation Method 1
The method of selective laser sintering (SLM method) is mentioned, inter alia, in that document
Implementation Method 2
when producing components by laser sintering
Data Source
AI summary
A composite powder containing microstructured particles obtainable by means of a method in which large particles are combined with small particles, whereinthe large particles have an average particle diameter within the range from 10 μm to 10 mm,the large particles comprise at least one polymer,the small particles are arranged on the surface of the large particles and/or distributed inhomogeneously within the large particles,the small particles comprise a calcium salt,the small particles have an average particle size within the range from 0.01 μm to 1.0 mm,wherein the particles of the composite powder have an average particle size d50 within the range from 10 μm to less than 200 μm, and the fine-particle fraction of the composite powder is less than 50% by volume.Preferred application areas of the composite powder encompass its use as additive, especially as polymer additive, as additive substance or starting material for compounding, for compounding, for the production of components, for applications in medical technology and/or in microtechnology and/or for the production of foamed articles.The invention therefore also provides components obtainable by selective laser sintering of a composition comprising a composite powder according to the invention, except for implants for uses in the field of neurosurgery, oral surgery, jaw surgery, facial surgery, neck surgery, nose surgery and ear surgery as well as hand surgery, foot surgery, thorax surgery, rib surgery and shoulder surgery.