Multi-layer Polyamide Filament for 3D Printing Warpage Reduction

Solution Overview

Problem

Polyamide-based resins used in 3D printing face issues with interlayer adhesiveness, warpage, and heat resistance due to rapid crystallization, limiting their applicability in material extrusion type 3D printing.

Innovation Solution

A multi-layer 3D printer material structure is developed, featuring an outer layer with a crystalline polyamide-based resin and a component that delays crystallization, optimizing thermal properties to enhance interlayer adhesiveness and heat resistance while reducing warpage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a crystalline polyamide-based resin having a high crystal melting temperature is used as 3D printer material, then heat resistance and rigidity are improved, but interlayer adhesiveness deteriorates and warpage occurs due to fast crystallization rate

Engineering Contradiction:

Improveheat resistanceVSAvoidinterlayer adhesiveness

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The filament is divided into a multi-layer structure with an inner layer containing the crystalline polyamide-based resin and an outer layer containing a resin with slower crystallization rate. This segmentation allows the inner layer to provide heat resistance while the outer layer controls the overall crystallization rate to prevent warpage and improve interlayer adhesiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different layers of the filament are assigned different resin compositions with specific local properties. The inner layer has high crystallinity for heat resistance, while the outer layer has modified crystallization characteristics. This local quality differentiation enables each layer to fulfill its specific function while working together as a unified material system.

Inventive Principle:

Principle #3Local quality

2Temperature

If a crystalline polyamide-based resin having a high crystal melting temperature is used as 3D printer material, then heat resistance is improved, but warpage increases due to fast crystallization rate

Engineering Contradiction:

Improveheat resistanceVSAvoidwarpage

Core Design Contradiction:

TemperatureVSShape

Solution Approach 1:

The filament is divided into a multi-layer structure with an inner layer containing the crystalline polyamide-based resin and an outer layer containing a resin with slower crystallization rate. This segmentation allows the inner layer to provide heat resistance while the outer layer controls the overall crystallization rate to prevent warpage and improve interlayer adhesiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different layers of the filament are assigned different resin compositions with specific local properties. The inner layer has high crystallinity for heat resistance, while the outer layer has modified crystallization characteristics. This local quality differentiation enables each layer to fulfill its specific function while working together as a unified material system.

Inventive Principle:

Principle #3Local quality

3Strength

If a multi-layer structure is formed to solve filament strength and moisture absorption problems, then individual properties are improved, but interlayer adhesiveness, warpage, and heat resistance problems remain unresolved

Engineering Contradiction:

Improvefilament strengthVSAvoidinterlayer adhesiveness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The invention changes the material composition parameters by incorporating a specific resin component in the outer layer that delays crystallization. This parameter change affects not only filament strength and moisture absorption but also controls the overall crystallization rate to improve interlayer adhesiveness and reduce warpage, resolving multiple problems simultaneously.

Inventive Principle:

Principle #35Parameter changes

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 improves the printability of 3D printer materials by achieving better interlayer adhesiveness and heat resistance with reduced warpage, allowing for more versatile industrial applications.

Implementation Method 1

a component that delays crystallization of the crystalline polyamide-based resin and has specific thermal properties

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Implementation Method 2

a raw material in the form of a filament composed of a thermoplastic resin is inserted into an extrusion head and while being fused by heating, continuously extruded from a nozzle region

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentEP3812130B13D printer material

Publication Date: 2023.02.22 MITSUBISHI CHEM CORP

Figure 1~2

AI summary

The present invention relates to a 3D printer material including an outer layer and an inner layer, in which a heat quantity of crystallization of the 3D printer material in differential scanning calorimetry is from 20 to 60 J/g, and the outer layer contains a resin composition (C) containing a crystalline polyamide-based resin (A) and a component (B) that delays crystallization of the crystalline polyamide-based resin (A).