Polyester TPE Filament for FFF Warpage Reduction
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Solution Overview
Problem
Medium to hard thermoplastic elastomers (TPEs) face challenges in fused filament fabrication (FFF) due to increased crystallinity and high freezing points, leading to warpage and poor mechanical properties in 3D printed parts, including delamination and cracks along the print lines.
Innovation Solution
Development of filaments comprising polyester thermoplastic elastomers with specific hard and soft segment compositions, exhibiting Shore D hardness of 41 or greater, and thermal properties of melting peak temperatures between 130°C to 205°C and crystallization peak temperatures between 50°C to 140°C, which are prepared using a method involving extrusion and cooling to form filaments suitable for FFF processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If medium to hard thermoplastic elastomers with increased crystallinity and high freezing points are used in FFF, then material strength and structural integrity are improved, but warpage and delamination occur during printing
Solution Approach 1:
The patent modifies the thermal parameters of the TPE material by adjusting the melting point to 130-205°C and crystallization point to 50-140°C, creating an optimal temperature window for FFF printing that prevents warpage while maintaining material strength
Solution Approach 2:
The invention uses copolyester thermoplastic elastomers with specific hard and soft segment compositions, combining different polymer segments to achieve both high strength and appropriate thermal properties for FFF processing
2Strength
If TPEs with high crystallinity are used to improve mechanical properties, then material strength increases, but cracks along print lines develop
Solution Approach 1:
The patent optimizes the crystallization temperature range to 50-140°C, which allows controlled crystallization during printing that maintains mechanical strength while preventing crack formation along print lines
Solution Approach 2:
The copolymer structure with distinct hard and soft segments provides local variations in properties, with hard segments providing strength and soft segments providing flexibility to prevent cracking
3Ease of manufacture
If TPE composition is modified to achieve appropriate melting and crystallization temperatures for FFF, then printability is improved, but material hardness must be precisely controlled
Solution Approach 1:
The patent establishes specific parameter ranges including melting point (130-205°C), crystallization point (50-140°C), and Shore D hardness (41 or greater), providing precise control over material properties for optimal FFF printing
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 resulting 3D printed articles exhibit reduced warpage, improved strength in the vertical direction, and enhanced surface appearance, with reduced cracks along the print lines and increased mechanical performance.
Implementation Method 1
a melting peak temperature (A), when the temperature is increased at a rate of 10°C/minute, in a range from about 130 to about 205 °C
Implementation Method 2
a crystallization peak temperature (B), when the temperature is decreased at a rate of 10°C/minute, in a range from about 50 to about 140 °C
Implementation Method 3
a 3D object is formed by extruding the composition through a nozzle to form layers as the composition hardens after extrusion
Data Source
AI summary
The disclosure generally relates to filaments and in particular, filaments for use in fused filament fabrication. The filaments may be made of polyester thermoplastic elastomers having advantageous shore D hardness characteristics and thermal properties. The use of the polyester thermoplastic elastomer (TPE) filaments result in 3D printed articles exhibiting desirable properties such as reduced warpage and improved surface appearance compared to articles not produced using polyester TPEs.