3D Metal Particles Production via Nested Powder and Binder Vents
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Solution Overview
Problem
Existing three-dimensional shaped article production methods face challenges in achieving high density and large size due to voids in metal powder layers and difficulties in binder escape during sintering, leading to reduced rigidity and incomplete densification.
Innovation Solution
A method involving the supply of a first metal powder with larger particles, a binder-containing liquid with smaller particles for internal penetration, and a second liquid with either lower concentration or larger particles for surface layer void creation, followed by sintering to remove binders effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal powder of large particles is used to form a layer, then the layer can be formed easily, but voids among particles become large leading to low density and reduced rigidity
Solution Approach 1:
The patent applies the nesting principle by introducing smaller metal particles (second metal powder with average particle diameter 1/10 to 1/2 of the first metal powder) into the voids between larger metal particles. This nested arrangement allows small particles to occupy the spaces between large particles, effectively increasing packing density while maintaining ease of layer formation.
Solution Approach 2:
The patent uses composite materials by combining two different metal powders with different particle size distributions. The first metal powder (larger particles) provides structural framework and ease of handling, while the second metal powder (smaller particles) fills voids to increase density. This composite approach resolves the contradiction between ease of manufacture and manufacturing precision.
2Manufacturing precision
If a metal powder of small particles is used to form a layer, then packing density may increase, but aggregation occurs forming blocks that prevent uniform spreading
Solution Approach 1:
The patent applies local quality by assigning different functions to different particle sizes: larger particles serve as the primary structural framework that ensures uniform spreading and ease of operation, while smaller particles are localized to fill voids between the larger particles. This spatial differentiation of particle functions resolves the contradiction between packing density and uniform spreading.
3Manufacturing precision
If a high density three-dimensional shaped article is produced, then rigidity improves, but vaporized binder cannot escape from the surface layer during sintering
Solution Approach 1:
The patent applies porous materials principle by intentionally creating a layered structure with different densities: the internal region has high density for rigidity, while the surface layer region has lower density with more voids. These controlled voids in the surface layer act as escape pathways for vaporized binder during sintering, preventing binder entrapment while maintaining overall high density of the article.
4Ease of manufacture
If only large metal particles are used, then layer formation is easy, but voids are large reducing rigidity
Solution Approach 1:
The patent uses the nesting principle where smaller metal particles are embedded within the voids of the larger particle framework. This nested structure allows the large particles to provide ease of layer formation while the small particles fill the voids to increase rigidity, resolving the contradiction between ease of manufacture and strength.
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 enables the production of high-density, large three-dimensional shaped articles by effectively filling voids with smaller particles and facilitating binder escape, resulting in improved rigidity and densification.
Implementation Method 1
a first liquid supply step of supplying a first liquid containing a binder and a second metal powder having a second average particle diameter that is an average particle diameter 1/10 or more and 1⁄2 or less the first average particle diameter to a portion of a constituent region of the three-dimensional shaped article in the layer
Implementation Method 2
when sintering the stacked body... a vaporized binder or the like cannot escape from the surface layer
Implementation Method 3
a sintering step of sintering a metal in the constituent region by heating a stacked body of the layers
Data Source
AI summary
A three-dimensional shaped article production method is a three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers and includes a first metal powder supply step of supplying a first metal powder having a first average particle diameter to a shaping table, a layer formation step of forming the layer by compressing the first metal powder supplied to the shaping table, a first liquid supply step of supplying a first liquid containing a second metal powder having a second average particle diameter and a binder to a portion of a constituent region of the three-dimensional shaped article, a second liquid supply step of supplying a second liquid containing at least either the second meal powder at a lower concentration than the first liquid or a third metal powder having a larger average particle diameter than the second average particle diameter and containing a binder to at least a portion of a surface layer region, and a sintering step of sintering a metal in the constituent region by heating a stacked body.