3D Printing Penetrating Liquid Functional Material for Uniform Interlayer Bonding
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Solution Overview
Problem
Current 3D printing methods face challenges in achieving uniform interlayer bonding and enhanced mechanical properties, particularly in multi jet fusion processes, where the distribution of energy absorbers across build material layers is uneven, leading to inconsistencies in thermal uniformity and part quality.
Innovation Solution
The use of a penetrating liquid functional material with non-Newtonian fluid properties, capable of absorbing electromagnetic radiation and converting it to thermal energy, is selectively deposited to fuse and bind build material layers, ensuring uniform energy distribution and improved interlayer bonding, while its structured network enhances mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional heat-assisted sintering is used to fuse build material layers, then material fusion is achieved, but uniform thermal energy distribution across layers is difficult to accomplish, leading to inconsistent interlayer bonding
Solution Approach 1:
The patent introduces an energy absorber material as an intermediary substance that is mixed into the build material layers. This energy absorber selectively absorbs electromagnetic radiation and converts it to thermal energy, acting as a mediator that enables uniform heat distribution throughout the layers without requiring external heating elements to penetrate and heat each layer uniformly.
Solution Approach 2:
The patent replaces traditional mechanical or external thermal heating systems with an electromagnetic radiation-based heating mechanism. By using electromagnetic radiation (such as infrared or microwave) that penetrates the build material and is converted to thermal energy by the energy absorber distributed throughout the material, the system achieves more uniform heating compared to external heat sources that struggle to penetrate and distribute heat evenly across multiple layers.
2Productivity
If electromagnetic radiation is used to cure or fuse materials, then curing efficiency is improved, but uniform energy absorption across the build material is challenging, resulting in non-uniform thermal distribution
Solution Approach 1:
The patent applies local quality by distributing energy absorber material throughout the build material layers. Different regions of the build material contain energy absorbers that locally convert electromagnetic radiation to thermal energy, ensuring that each region absorbs and generates heat uniformly according to its local energy absorber concentration, thereby achieving overall uniform thermal distribution.
Solution Approach 2:
The patent changes the physical and chemical parameters of the build material by incorporating energy absorber substances with specific electromagnetic absorption characteristics. By selecting energy absorbers with appropriate absorption coefficients and distribution densities, the system optimizes the conversion of electromagnetic radiation to thermal energy, achieving uniform energy distribution and consistent curing across all layers.
3Strength
If material layers are fused using conventional methods, then layer bonding is achieved, but mechanical properties and interlayer strength remain inconsistent
Solution Approach 1:
The energy absorber material serves as an intermediary that ensures consistent energy distribution during the fusion process. By uniformly distributing thermal energy throughout the build material layers through electromagnetic radiation absorption, the energy absorber mediates the fusion process to achieve consistent interlayer bonding and reliable mechanical properties across the entire printed part.
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 results in 3D objects with enhanced interlayer bonding and mechanical strength, achieved through uniform thermal energy distribution and the formation of a structured network within the build material, leading to improved part uniformity and stability.
Implementation Method 1
The penetrating liquid functional material contains an energy absorber. As such, the penetrating liquid functional material is capable of absorbing electromagnetic radiation and converting the absorbed radiation to thermal energy, which in turn melts or sinters the build material that is in contact with the penetrating liquid functional material.
Implementation Method 2
The penetrating liquid functional material is capable of penetrating into the layer of the build material and spreading onto the exterior surface of the build material and substantially uniformly throughout the build material layer.
Implementation Method 3
This is unlike traditional machining processes, which often rely upon the removal of material to create the final part. Materials used in 3D printing often require curing or fusing, which for some materials may be accomplished using heat-assisted sintering
Data Source
AI summary
In a 3D printing method, a first layer of a build material is applied. A part layer is patterned by selectively applying a penetrating liquid functional material (PLFM) on at least a portion of the first layer. The PLFM includes (in amounts by weight based on total wt % of the PLFM): from about 5%-15% of a first metal oxide nanoparticle having a particle size ranging from about 0.5 nm up to 10 nm, from about 0.25%-10% of a second metal oxide nanoparticle having at least one dimension greater than 10 nm, from about 1%-10% of an electromagnetic radiation absorber, from about 5%-50% of an organic solvent, a surfactant, and a balance of water. The first layer having the PLFM applied thereon is exposed to electromagnetic radiation, whereby the portion of the first layer at least partially fuses to form the part layer.