Polymer Microsphere Formation Using Zoned Fall-Chamber Atomization
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Solution Overview
Problem
Current additive manufacturing methods for producing powders are slow, inefficient, and costly, often resulting in powders with varying sizes and densities that lack sphericity, making them unsuitable for refined print processes and requiring material-specific processes.
Innovation Solution
A system comprising a melt chamber, vertical extruder, atomizer, and fall chamber with controlled zones for producing high-quality spherical polymer powders and microfibers, allowing for the production of polymer-based print materials with controlled properties, including additives, using a single-step process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional powder forming methods are used, then production cost and time are reduced, but manufacturing precision and sphericity of powders deteriorate
Solution Approach 1:
The patent utilizes phase transition of polymer material from solid to molten state through controlled heating in the melt chamber, then rapidly solidifies upon contact with cooling surfaces in the fall chamber. This phase transition enables precise control over particle morphology and sphericity while maintaining high production rates through continuous processing.
Solution Approach 2:
The invention replaces conventional mechanical powder forming methods with a melt-based system where polymer is heated, extruded, and solidified under controlled conditions. This substitution eliminates the need for mechanical compression and molding operations, achieving superior sphericity and uniformity while increasing production efficiency.
2Manufacturing precision
If material-specific processes are used for each polymer type, then manufacturing precision of powder properties is improved, but device complexity and process variability increase
Solution Approach 1:
The patent employs a universal melt-based processing system that can handle multiple polymer types (thermoplastics, elastomers, composites) through a single integrated apparatus. The system achieves material-specific powder properties by adjusting processing parameters (temperature, residence time, cooling rate) rather than requiring different equipment or fundamentally different processes for each material type.
Solution Approach 2:
The invention controls powder properties by varying processing parameters such as melt temperature, extrusion rate, and cooling conditions within a single unified process framework. This approach enables precise control over particle size, sphericity, and density for different polymer materials without increasing device complexity or requiring separate material-specific processes.
3Manufacturing precision
If conventional extrusion methods are used, then device complexity is reduced, but manufacturing precision of particle size and shape deteriorates
Solution Approach 1:
The patent divides the extrusion and solidification process into distinct functional zones: a melt chamber for heating and homogenization, an extrusion section for shaping, and a fall chamber with cooling surfaces for controlled solidification. This segmentation allows each zone to be optimized for its specific function, achieving high particle uniformity and sphericity through coordinated control of multiple process stages.
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
Enables rapid production of high-quality spherical powders and microfibers with controlled properties, suitable for various additive manufacturing technologies, allowing for parts with variable densities and improved elastomeric properties, and enabling the use of existing AM technologies to produce parts with tailored characteristics.
Implementation Method 1
an atomizer that atomizes the polymer melt from the vertical extruder and that distributes the atomized polymer melt
Implementation Method 2
a fall chamber comprising a plurality of zones into which the atomized polymer melt is distributed
Data Source
AI summary
The embodiments are and include at least an apparatus, system and method for forming print material particles for additive manufacturing (AM) printing. The apparatus, system and method include at least a melt chamber comprising a polymer melt; a vertical extruder that fluidically receives the polymer melt; an atomizer that atomizes the polymer melt from the vertical extruder and that distributes the atomized polymer melt; a fall chamber comprising a plurality of zones into which the atomized polymer melt is distributed; and a collector to receive the print material particles formed of the atomized polymer melt after falling through the plurality of zones.