Olefin Block Copolymer Additive Manufacturing Warpage Control
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Solution Overview
Problem
Current additive manufacturing techniques, such as fused filament fabrication, face challenges with warpage and lack of adhesion in the z-direction when printing polyolefins like polypropylene and polyethylene, limiting the use of these materials due to their crystalline formation and requiring additional fillers that compromise mechanical properties.
Innovation Solution
A method using an olefin block copolymer comprising an isotactic polypropylene block and a polyethylene rich block, which is heated and extruded through a nozzle to form layers adhered to a base, allowing for the creation of additive manufactured parts without the need for solid fillers, thus avoiding warpage and enhancing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If HDPE or polypropylene is used for additive manufacturing, then the material provides good mechanical properties and processability, but the material warps due to crystalline formation
Solution Approach 1:
The patent changes the molecular structure parameter by using block copolymer composition with specific crystallinity control. The olefin block copolymer has controlled crystalline regions that prevent warping while maintaining mechanical strength. The specific composition ratio and molecular weight distribution are optimized to achieve this balance.
Solution Approach 2:
The patent uses composite material structure through block copolymer composition, combining different olefin blocks with varying crystallinity. This composite molecular structure allows the material to exhibit both good mechanical properties and reduced warping, as the different blocks compensate for each other's tendencies.
2Shape
If filler is added to reduce warping, then warping is lessened, but the mechanical properties are substantially reduced
Solution Approach 1:
The patent extracts the warping control function from external fillers and incorporates it into the base polymer structure itself. By using block copolymer with inherent crystallinity control, the material achieves warping resistance without needing additional filler additives that would compromise mechanical properties.
Solution Approach 2:
The block copolymer material is self-sufficient for warping control through its inherent molecular structure. The controlled crystalline formation within the copolymer itself provides the necessary warping resistance, eliminating the need for external filler materials to provide this function.
3Manufacturing precision
If polyolefin is used for additive manufacturing, then the material provides good processability and dimensional stability, but the material lacks adhesion in the z-direction
Solution Approach 1:
The patent changes the surface energy parameter by using block copolymer composition that balances hydrophobicity with interlayer adhesion. The specific olefin block ratios and molecular weight distribution are optimized to provide sufficient surface energy for layer adhesion while maintaining the overall dimensional stability and processability of polyolefin.
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 successful printing of rigid polyolefin parts with improved dimensional stability and adhesion, maintaining the desirable properties of polyolefins while overcoming the limitations of warpage and adhesion issues associated with traditional methods.
Implementation Method 1
thermoplastic polymer powders are melted and extruded, for example, using filaments that are advanced and heated through a nozzle
Implementation Method 2
heated and extruded through a nozzle to form an extrudate deposited on a base
Implementation Method 3
form successive layers of the material adhered to the initial layer
Data Source
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AI summary
A method of fused filament fabrication (FFF) additive manufacturing comprises employing an olefin block copolymer. The method allows for the additive manufacturing article that retains the desirable mechanical properties of polyolefins such as polyethylene or polypropylene without experiencing the problems inherent in FFF printing of polyethylene or polypropylene particularly in the absence of solid fillers. In a particular embodiment, the additive manufactured article is comprised of the olefin block copolymer is comprised of block composite or crystalline block composite polymer or mixture thereof comprising the olefin block copolymer, wherein the olefin block copolymer is comprised of an isotactic propylene block and a polyethylene rich block.