Binder Jetting Polymer 3D Printing Temperature Control
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Solution Overview
Problem
The binder jetting process for 3D printing using polymer powder results in components with low strength, high porosity, and dimensional inaccuracies due to limited binder application, leading to compromised strength and stability, and requires extensive post-treatment for improved strength.
Innovation Solution
Heating the starting material and binder to controlled temperatures accelerates the dissolution process, increases binder viscosity, and allows for higher binder application, reducing migration and enhancing the strength and dimensional stability of the printed components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binder is applied to particle layer at room temperature, then component strength is improved, but binder migration occurs and surface quality deteriorates
Solution Approach 1:
The patent applies temperature parameter changes by heating the particle layer to a predetermined temperature before binder application. This temperature increase accelerates the dissolution process of the binder into the particles and increases binder viscosity, thereby preventing binder migration while maintaining component strength and improving surface quality.
2Manufacturing precision
If binder application is limited to 10% of void space, then binder migration is prevented, but component strength remains low
Solution Approach 1:
By changing the temperature parameter of the particle layer, the patent enables the dissolution process to proceed rapidly at accelerated rates. This allows sufficient binder to be applied (exceeding the conventional 10% void space limitation) without causing migration, as the binder quickly dissolves into the heated particles and forms strong bonds, thereby improving both dimensional accuracy and component strength.
3Manufacturing precision
If dissolution process is accelerated by heating, then binder migration is reduced, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by heating the particle layer before binder application. This pre-heating prepares the particles to rapidly absorb and dissolve the binder, ensuring quick dissolution and preventing migration. The energy input is concentrated in a controlled manner during the critical dissolution phase, achieving dimensional stability while managing energy consumption efficiently.
4Use of energy by moving object
If room temperature processing is used, then energy consumption is reduced, but component porosity remains high and strength is low
Solution Approach 1:
The patent changes the temperature parameter from room temperature to a predetermined elevated temperature during the binder application process. This temperature increase accelerates the dissolution process, allowing binder to effectively penetrate and bond with particles, thereby reducing component porosity and significantly improving strength while maintaining controlled energy consumption through localized and time-limited heating.
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 produces components with significantly increased strength, reduced shrinkage, and improved surface smoothness, enabling the production of parts with higher tensile strength and better geometric accuracy, while simplifying the removal process and reducing post-treatment requirements.
Implementation Method 1
heating the starting material to a predetermined first temperature before applying a binding agent to the particle layer in a build space, in order to accelerate a dissolution process between the particles and the binding agent
Implementation Method 2
the accelerated dissolution process also significantly accelerates the increase in the viscosity of the binder, which greatly reduces the migration of the binder into neighboring areas
Implementation Method 3
when a polymerizable binder is used, the dissolved portion of the particles initiates polymerization of the binder, which increases viscosity even further
Data Source
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AI summary
A method for producing a three-dimensional molded part using an additive manufacturing process is provided, wherein - in a first step a powdered starting material is introduced as a particle layer into a build chamber, - in a second step a liquid binder is selectively applied to the particle layer, wherein the steps are repeated until the molded part is built up, and wherein a polymer powder is used as the starting material and is heated to a predetermined first temperature.