Polyaryletherketone Powder MVR Optimization for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing processes face challenges in achieving optimal process windows and mechanical stability for 3D articles due to insufficient melting properties of polymers, leading to delamination and instability issues.
Innovation Solution
A composition comprising thermoplastic polymers, specifically polyaryletherketones and their copolymers, with a defined melt volume rate (MVR) between 5 and 55 cm3/10 min, optimized for improved flowability and melting properties, is developed for use in additive manufacturing. This composition includes a process for manufacturing and using the polymer in laser sintering, ensuring enhanced bonding and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the building temperature is increased to improve melting properties and bonding, then the bonding of melted mass with subjacent layers is improved, but the powder cake may melt in the building area causing instability
Solution Approach 1:
The patent changes the physical-chemical parameters of the polymer by defining a specific MVR range (5-55 cm³/10min) to optimize the process window. This parameter control allows the polymer to melt sufficiently for bonding while maintaining powder cake stability, resolving the temperature contradiction.
Solution Approach 2:
The patent applies preliminary thermal treatment to the polymer powder before additive manufacturing to optimize its melting properties. This pre-treatment ensures the polymer has the correct flow and melting characteristics, enabling successful bonding at controlled temperatures without powder cake degradation.
2Strength
If the polymer has high melting properties to ensure bonding, then layer bonding is improved, but the process window becomes restricted making manufacturing difficult
Solution Approach 1:
The patent optimizes the MVR parameter to a specific range (5-55 cm³/10min) that simultaneously improves layer bonding and widens the process window. This parameter optimization makes the manufacturing process more robust and easier to control while maintaining strong interlayer bonding.
3Stability of the object's composition
If the polymer melts sufficiently for bonding, then interdiffusion between layers is improved, but the mechanical stability of the 3D article decreases due to delamination
Solution Approach 1:
The patent defines an optimal MVR range (5-55 cm³/10min) that ensures sufficient melting for interdiffusion and bonding while preventing excessive melting that would cause delamination. This parameter control achieves the balance needed for mechanical stability.
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 composition exhibits superior flowability and homogenous structure, resulting in improved rheological characteristics, mechanical properties, and dimensional stability, allowing for the production of 3D objects with enhanced tensile strength and elongation at break, thus addressing the stability and accuracy issues in additive manufacturing.
Implementation Method 1
layers are selectively melted and solidified
Implementation Method 2
layers are selectively melted and solidified
Implementation Method 3
the composition has a melt volume rate (MVR) of at least 5 cm3/10 min, more preferred at least 10 cm3/10 min
Implementation Method 4
by selectively melting and solidifying, respectively the desired structures are manufactured
Implementation Method 5
Processes which are encompassed by additive manufacturing to use powdery material are, e. g., sintering, melting or gluing by a binder
Implementation Method 6
bonding of the melted mass with the subjacent layers of the 3D structure, as interdiffusion can take place only in the melted mass
Data Source
AI summary
Disclosed is a composition including at least one polymer, wherein the polymer is in the form of a powder, and wherein the polymer includes at least one thermoplastic polymer. The thermoplastic polymer is selected from at least one polyaryletherketone and/or a copolymer and/or a block-copolymer and/or a polymer blend thereof, wherein the composition has a melt volume rate (MVR) of at least 5 cm3/10 min and a process of manufacturing and a use thereof. Also disclosed are a process for the manufacture of a construction element and the construction element thereof.