3D Printing Polyamide Blend with Fusing Agent for Reduced Embrittlement
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Solution Overview
Problem
3D printing technologies face challenges in producing objects with high strain at break and reduced embrittlement due to the formation of larger crystal spherulites in polymer build materials, which can lead to brittleness and limitations in material properties.
Innovation Solution
A 3D printing method using a polymer build material comprising a blend of polyamide 12 and polyamide 11, with polyamide 12 making up 95-99% and polyamide 11 making up 1-5% of the total weight, where a fusing agent is selectively applied and heated to fuse the material, disrupting the crystal structure and enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal fusing is used to join polymer layers in 3D printing, then manufacturing capability is improved, but crystal spherulite formation causes embrittlement and reduces strain at break
Solution Approach 1:
The patent changes the thermal processing parameters by implementing a two-stage heating process: first heating to a fusing temperature (above melting point) to join layers, then heating to an annealing temperature (below melting point but above glass transition) to control crystal spherulite formation. This parameter modification resolves the contradiction by preventing embrittlement while maintaining manufacturing capability.
Solution Approach 2:
The patent applies a preliminary annealing treatment after the main fusing process. This preliminary action of controlled heating at annealing temperature modifies the crystal structure before final cooling, preventing excessive spherulite growth that would cause embrittlement, thereby preserving both manufacturing capability and material strength.
2Productivity
If rapid cooling is used after heating polymer build material, then productivity is improved, but large crystal spherulites form causing brittleness
Solution Approach 1:
The patent implements a preliminary annealing heating step before final cooling. This preliminary action of controlled heating at annealing temperature (between glass transition and melting points) modifies the crystal structure in advance, preventing rapid cooling from causing large spherulite formation, thus maintaining both productivity and preventing brittleness.
3Manufacturing precision
If high heating temperature is used to fuse polymer layers, then manufacturing precision is improved, but material degradation and void formation occur
Solution Approach 1:
The patent changes the thermal processing parameters by implementing a two-stage heating process: first heating to a fusing temperature (above melting point) to ensure proper layer bonding and manufacturing precision, then heating to an annealing temperature (below melting point but above glass transition) to control crystal spherulite formation. This parameter modification resolves the contradiction by preventing embrittlement while maintaining manufacturing capability.
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 method results in 3D printed objects with increased strain at break and reduced embrittlement, as demonstrated by higher elongation at break values and smaller spherulite sizes, improving the material's elastic properties and reducing voids.
Implementation Method 1
An infrared radiation (IR) absorbing fusing agent (e.g., containing carbon black as the IR absorbing species) can be selectively deposited on the selected region of the polymer build material. The fusing agent(s) is capable of penetrating into the layer of the build material and spreading onto the exterior surface of the polymer build material particles. This fusing agent is capable of absorbing IR radiation and converting the absorbed radiation to thermal energy, which in turn melts or fuses the polymer build material that is in contact with the fusing agent.
Implementation Method 2
Some 3D printing techniques are considered additive processes because they involve the application of successive layers of components. 3D printing may use annealing and fusing of the building material, which may be accomplished using light polymerization, thermal fusing, heat-assisted extrusion, melting, and/or chemical binding techniques.
Implementation Method 3
3D printing technologies face challenges in producing objects with high strain at break and reduced embrittlement due to the formation of larger crystal spherulites in polymer build materials, which can lead to brittleness and limitations in material properties.
Data Source
AI summary
Compositions including polyamides and methods of employing compositions including polyamides are described herein. For instance, composition for three-dimensional (3D) printing can include a polymer build material comprising of at least two polyamides including a first polyamide and a second polyamide, where the first polyamide is present in an amount ranging of from about 95% to about 99% of a total weight of the polymer build material and where the second polyamide is present in an amount ranging of from about 1% to about 5% of the total weight of the polymer build material.