Multilayer 3D Printing Filament for Warpage Control
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Solution Overview
Problem
Fused deposition modeling (FDM) three-dimensional printers face challenges with warpage and dimensional accuracy due to temperature control issues and instability in multilayer filament production, leading to difficulties in achieving intended properties and functions in three-dimensional shaped objects.
Innovation Solution
A three-dimensional modeling material with a multilayer structure comprising specific thermoplastic resins having different shear storage elastic moduli and crystallization temperatures, used in a core-sheath filament design, which allows for improved interlayer adhesion and heat resistance without precise temperature control, and a nozzle mechanism for stacking molten resins to form a multilayer structure during extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ABS resin or PP is used for heat resistance and strength, then the shaped article has good mechanical properties, but warpage occurs during modeling and dimensional accuracy deteriorates
Solution Approach 1:
The patent uses a multilayer filament structure combining ABS resin (for heat resistance and strength) with PLA resin or other materials (for low warpage). This composite approach allows the final object to simultaneously achieve high strength from the ABS layer and dimensional accuracy from the low-warpage layer, resolving the contradiction between mechanical properties and manufacturing precision
Solution Approach 2:
The filament is divided into multiple functional layers: an outer layer with low warpage characteristics and an inner core layer with high strength characteristics. This segmentation allows each layer to perform its specific function independently, with the outer layer controlling dimensional stability and the inner layer providing structural strength
2Manufacturing precision
If temperature of modeling area is precisely controlled to prevent warpage, then dimensional accuracy is improved, but the three-dimensional printer becomes large and expensive
Solution Approach 1:
The filament material itself provides the warpage prevention function through its composition and multilayer structure, eliminating the need for complex external temperature control systems. The material's inherent properties (low coefficient of thermal expansion in certain layers) enable dimensional accuracy without requiring sophisticated environmental control infrastructure
3Manufacturing precision
If multilayer filament structure is used to prevent warpage, then dimensional accuracy is improved, but it is difficult to appropriately form the filament due to unstable ejection and diameter control
Solution Approach 1:
The patent optimizes specific parameters including the viscosity ratio between layers (outer layer viscosity ≥ 0.8 times inner layer viscosity), layer thickness ratios, and extrusion temperatures to ensure stable multilayer filament formation. These parameter adjustments enable reliable co-extrusion while maintaining the functional multilayer structure
4Adaptability or versatility
If multilayer structure is used to impart specific functions to different portions, then adaptability is improved, but interlayer adhesion becomes difficult to control due to viscosity differences
Solution Approach 1:
The patent carefully controls the viscosity relationship between layers (outer layer viscosity ≥ 0.8 times inner layer viscosity) and adjusts extrusion parameters to ensure proper interlayer adhesion. This parameter optimization allows different resins with varying properties to be combined while maintaining reliable bonding between layers
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 prevents warpage and enhances heat resistance and strength of three-dimensional objects, enabling high-quality industrial applications without the need for precise temperature control and allowing for varied resin combinations to impart specific functions to intended object portions.
Implementation Method 1
a raw material in the form of a filament formed of a thermoplastic resin is first inserted into an extrusion head and continuously extruded from a nozzle portion provided in the extrusion head onto an X-Y plane substrate in a chamber while being heat-fused
Implementation Method 2
The extruded resin is deposited on a previously deposited resin stack and fused thereto. As the extruded resin is cooled, it is integrated with the previously deposited resin stack and solidified
Implementation Method 3
As the extruded resin is cooled, it is integrated with the previously deposited resin stack and solidified
Data Source
AI summary
Provided is a three-dimensional modeling material used for a fused deposition modeling three-dimensional printer. The three-dimensional modeling material has a multilayer structure and contains, in respective different layers, a thermoplastic resin (A) having a shear storage elastic modulus (G′) of 1.00×107 Pa or less as measured at 100° C. and 1 Hz and a thermoplastic resin (B) having a shear storage elastic modulus (G′) of more than 1.00×107 Pa as measured at 100° C. and 1 Hz.