Particulate Build Materials for 3D Printing
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Solution Overview
Problem
The limitations of three-dimensional (3D) digital printing in commercial production due to the restricted range of materials used, which hinders its widespread adoption in industries like aviation and medicine, where rapid prototyping and customization are essential.
Innovation Solution
Development of a particulate build material for 3D printing comprising polymer particles with a polyolefin polymer backbone, including crosslinkable components such as maleic anhydride-containing side chains, thiol-containing side chains, or glycidyl polyhedral oligomeric silsesquioxane, combined with a fusing agent that absorbs electromagnetic energy to facilitate thermal fusion and chemical crosslinking, enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials are used in 3D printing, then the printing process is simple, but the mechanical strength and commercial applicability are limited
Solution Approach 1:
The patent uses composite materials by combining polymer particles with crosslinkable components (maleic anhydride, thiol, or glycidyl polyhedral oligomeric silsesquioxane) to create a multi-functional build material that achieves both high mechanical strength and commercial applicability while maintaining processability in existing 3D printing systems
2Strength
If crosslinkable components are added to polymer particles, then mechanical strength is improved, but the material formulation becomes more complex
Solution Approach 1:
The patent merges the crosslinkable component directly into the polymer particle structure itself, combining the base polymer with crosslinking functionality in a single integrated material formulation, which simplifies the manufacturing process while achieving enhanced mechanical properties through post-printing crosslinking
3Reliability
If a fusing agent with radiation absorber is used, then thermal fusion and crosslinking are enhanced, but the printing process becomes more complex
Solution Approach 1:
The patent introduces a fusing agent containing a radiation absorber as an intermediary substance that mediates between the electromagnetic energy source and the polymer particles, enabling controlled thermal fusion and crosslinking while maintaining compatibility with existing 3D printing hardware and processes
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 enables the production of 3D printed objects with high strength and resolution, achieving mechanical strengths of up to 20,000 MPa and allowing for the creation of complex parts with improved durability and precision.
Implementation Method 1
a radiation absorber that absorbs electromagnetic energy and converts the electromagnetic energy to heat
Implementation Method 2
the polymer particles further including a crosslinkable component... a multifunctional compound reactive with the crosslinkable component to crosslink the crosslinkable component
Data Source
AI summary
A particulate build material for three-dimensional printing can include from about 80 wt % to 100 wt % polymer particles having an average particle size from about 10 μm to about 125 μm. The polymer particles can have a polyolefin polymer backbone with from about 90 mol % to 100 mol % polypropylene polymeric units and from 0 mol % to about 10 mol % polyethylene polymeric units. The polymer particles can further include a crosslinkable component in the form of a maleic anhydride-containing side chain appended to the polyolefin polymer backbone, a thiol-containing side chain appended to the polyolefin polymer backbone, a glycidyl polyhedral oligomeric silsesquioxane compounded with the polyolefin polymer backbone, or a combination thereof.