Nanoparticle Binder Core-Shell 3D Printing

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Solution Overview

Problem

Current 3D printing technologies face challenges in efficiently forming complex three-dimensional parts with varying material compositions and structures, particularly in achieving uniform bonding and structural integrity using polymer binders and metal nanoparticle binders.

Innovation Solution

A 3D printer system that includes a spreader for distributing build material powder and a printhead for selectively depositing polymer and metal nanoparticle binders, allowing for the formation of layered structures with controlled energy application to create a green body, which is then processed to form a brown body with enhanced strength through annealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polymer binders are used to form 3D printed parts, then ease of manufacture is improved, but structural strength and integrity deteriorate

Engineering Contradiction:

Improveease of manufactureVSAvoidstructural strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses composite materials by combining polymer binders with metal nanoparticle binders in a core-shell structure. The polymer binder provides ease of manufacture and binding functionality, while the metal nanoparticle binder enhances structural strength and integrity. This composite approach allows the system to simultaneously achieve both ease of manufacture and high structural strength that neither material could provide alone.

Inventive Principle:

Principle #40Composite materials

2Strength

If metal nanoparticle binders are used to enhance structural strength, then strength is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the binder system into two distinct functional components: a polymer binder component for ease of manufacture and a metal nanoparticle binder component for structural strength. This segmentation allows each component to be optimized independently and simplifies the overall manufacturing process by clearly defining the role of each material, thereby reducing manufacturing complexity while maintaining high structural strength.

Inventive Principle:

Principle #1Segmentation

3Reliability

If uniform bonding is achieved throughout the part, then structural integrity is improved, but manufacturing time increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent implements local quality through the core-shell structure where different binder compositions are placed in different regions. The polymer binder is used in regions requiring ease of manufacture and lower temperature processing, while metal nanoparticle binders are used in core regions requiring high structural strength. This localized differentiation achieves uniform bonding and structural integrity throughout the part while optimizing manufacturing time by not using expensive or time-consuming processes throughout the entire part.

Inventive Principle:

Principle #3Local quality

4Productivity

If debinding time is reduced, then productivity is improved, but risk of warping or cracking increases

Engineering Contradiction:

Improvedebinding timeVSAvoidwarping or cracking

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent uses the polymer binder as an intermediary material that facilitates controlled debinding. The polymer binder is designed to decompose at lower temperatures and rates compared to traditional binders, enabling reduced debinding time while minimizing thermal stress and chemical reactions that could cause warping or cracking. The metal nanoparticle binder then maintains structural integrity during and after the rapid debinding process, preventing defects.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system enables the fabrication of 3D parts with improved structural strength and integrity by controlling the distribution and bonding of materials, reducing debinding time and preventing warping or cracking, and achieving high tensile strength in the final product.

Implementation Method 1

The metal nanoparticle binder may promote interparticle bonding of the build material powder and/or may increase the interparticle friction between the build material powder

Methodology Applied

Scientific EffectInterparticle bonding: Chemical Bonding

Implementation Method 2

a printhead for selectively depositing polymer and metal nanoparticle binders

Methodology Applied

Scientific EffectSelective deposition: Deposition (physical)

Implementation Method 3

a spreader for distributing build material powder

Methodology Applied

Scientific EffectSpreading:

Implementation Method 4

The brown body may be further processed by annealing to form the 3D part

Methodology Applied

Scientific EffectAnnealing: Annealing

Data Source

PatentUS11878346B2Objects having cores with nanoparticle binders

Publication Date: 2024.01.23 PERIDOT PRINT LLC

AI summary

According to examples, an object may include a shell including a polymer binder and build material powder; and a core at least partially encompassed by the shell, the core including build material powder and a metal nanoparticle binder.