Pillar-like Resin Powder for Solid Freeform Fabrication
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Solution Overview
Problem
Resin powders used in solid freeform fabrication often result in poor smoothness of the powder surface during recoating and degrade the surface properties of the fabricated objects due to the absence of fluidizers, which affect the quality and accuracy of the final product.
Innovation Solution
The development of resin powder with resin particles having a significantly pillar-like form and a concave portion on the circumferential side surface, which reduces particle resistance and enhances flowability, thereby improving the smoothness of the powder surface and the surface properties of the solid freeform fabrication objects without the need for inorganic fluidizers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional resin powder is used in solid freeform fabrication, then the fabrication process can proceed, but the powder surface smoothness deteriorates and surface properties of the fabricated object degrade
Solution Approach 1:
The invention changes the geometric parameters of the resin particles by creating a pillar-like shape with specific dimensions (height 50-200 μm, diameter 20-100 μm, aspect ratio 0.5-2.0) and surface features (concave portions with depth 1-10 μm). These parameter changes improve powder flowability and packing density, resulting in smoother powder surfaces during recoating without requiring fluidizers.
2Ease of operation
If fluidizers are added to improve powder flowability, then the powder surface smoothness improves, but the complexity of the material composition increases and inorganic contaminants are introduced
Solution Approach 1:
The invention extracts and eliminates the need for fluidizers from the powder composition. By designing resin particles with inherent pillar-like geometry and concave surface features, the powder achieves self-flowing properties without requiring additional inorganic fluidizing agents, thus simplifying the material composition while maintaining excellent flowability.
Solution Approach 2:
The resin particles are designed to serve their own flowability needs through their geometric structure. The pillar-like shape with concave portions creates interparticle voids and reduces contact area, enabling the particles to flow and pack efficiently on their own without external fluidizing agents,实现ing self-service flowability.
3Manufacturing precision
If resin particles with complex geometry are used to improve flowability, then the powder surface smoothness improves, but the manufacturing complexity of the particles increases
Solution Approach 1:
The invention employs pillar-like particles with curved concave portions on their surface rather than sharp edges or complex irregular shapes. This curved geometry improves flowability and packing while being manufacturable through conventional particle formation techniques, balancing geometric complexity with manufacturing ease.
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 resin powder with pillar-like particles achieves excellent smoothness during recoating and enhances the surface properties of the solid freeform fabrication objects, ensuring improved dimension accuracy and mechanical strength without the use of fluidizers.
Implementation Method 1
selectively irradiates a thin layer of powder of metal, ceramics, or resin with laser beams to melt the powder to cause it to adhere to each other
Implementation Method 2
melt the powder to cause it to adhere to each other to form a layer
Implementation Method 3
resin particles having a significantly pillar-like form including resin particles having a concave portion on the circumferential side surface, which reduces particle resistance and enhances flowability
Data Source
AI summary
A resin powder for solid freeform fabrication includes resin particles having a significantly pillar-like form including resin particles having a concave portion on the circumferential side surface.