3D Polymeric Article Formation via Solution Precipitation
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Solution Overview
Problem
Current additive manufacturing methods for polymers, such as material extrusion, are limited by the need for melting and solvent evaporation, which restricts the types of materials that can be fabricated, especially for high-melting-point polymers like PEEK and piezoelectric materials like PVDF, and can result in deformation and detachment issues during printing.
Innovation Solution
The method involves providing a polymeric solution dissolved in a solvent and a non-solvent where the solvent is miscible but the polymer is insoluble, allowing the polymer to precipitate as a solid when injected into the non-solvent in a predetermined 3D pattern, eliminating the need for melting and solvent evaporation, and enabling the formation of complex geometries with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material extrusion is used for polymer additive manufacturing, then manufacturing efficiency and dimensional accuracy are improved, but material selection is limited to thermoplastics that can be melted
Solution Approach 1:
The invention changes the fundamental processing parameter from thermal melting to solvent-based dissolution and precipitation. By dissolving polymers in solvents and precipitating them in non-solvents, the method enables fabrication of high-melting-point polymers (PEEK, PTFE, PVDF) that cannot be processed by conventional extrusion, thus expanding material versatility while maintaining manufacturing efficiency
Solution Approach 2:
The invention replaces the thermal-mechanical extrusion system with a solution-based dispensing and precipitation system. Instead of melting and extruding polymer through heat and pressure, the method dissolves polymer in solvent, dispenses the solution, and precipitates solid polymer structure in non-solvent environment, enabling new material possibilities
2Strength
If high-melting-point polymers like PEEK are fabricated using material extrusion, then desired material properties are achieved, but thermal stress causes warping and detachment during printing
Solution Approach 1:
The invention changes the processing temperature parameter from high-temperature melting (above polymer melting point) to room temperature or low temperature solution processing. By working with polymer solutions at temperatures below the melting point, thermal stress, warping, and detachment issues are eliminated while maintaining the ability to fabricate high-melting-point polymers like PEEK and PTFE
Solution Approach 2:
The invention introduces solvent and non-solvent as intermediary substances to enable polymer processing. The solvent dissolves the polymer to create a printable solution, and the non-solvent environment triggers precipitation of solid polymer structure, avoiding direct thermal processing and associated defects
3Manufacturing precision
If vat photopolymerization is used for additive manufacturing, then complex geometries and high precision are achieved, but photocurable resin cost is prohibitive
Solution Approach 1:
The invention replaces expensive photocurable resin with inexpensive polymer powders dissolved in common solvents. The polymer solution can be prepared at low cost using readily available materials, and the precipitation process in non-solvent environment produces the final solid structure, significantly reducing material costs while maintaining geometric precision through controlled dispensing
4Adaptability or versatility
If direct ink writing is used for additive manufacturing, then material versatility is improved, but fluid gel or ink with suitable viscosity is required
Solution Approach 1:
The invention changes the material state parameter from requiring pre-formulated fluid gel or ink to using polymer dissolution in solvent. By controlling polymer concentration and solvent type, the solution achieves appropriate viscosity for dispensing, simplifying material preparation while expanding versatility to include high-melting-point polymers and piezoelectric materials like PVDF
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
This approach expands the range of polymers that can be fabricated, allows for room temperature printing, reduces equipment and costs, and produces self-supporting structures with tunable properties, including high beta phase content for piezoelectric materials, enhancing mechanical and electrical properties.
Implementation Method 1
allowing the polymer to precipitate as a solid when injected into the non-solvent in a predetermined 3D pattern
Data Source
AI summary
The disclosure relates to methods of forming three-dimensional (3D) polymeric articles and additive manufacturing apparatuses for the same. The methods include providing a polymeric solution comprising a polymer dissolved in a solvent; providing a non-solvent, wherein the solvent is miscible in the non-solvent, and the polymer is insoluble in the non-solvent; and injecting the polymeric solution into the non-solvent in a pre-determined 3D pattern to provide a 3D polymeric article.