3D Printing Stabilizer for Polymer Oxidation Control

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Solution Overview

Problem

3D printing of polymeric materials faces issues with thermal degradation and oxidation due to prolonged exposure to high temperatures in oxygen-containing environments, leading to discoloration and reduced recyclability.

Innovation Solution

A detailing agent with a stabilizer is selectively applied to the polymeric build material, which evaporates at coalescence/fusing temperatures, reducing oxidation and thermal degradation by cooling the surface and minimizing exposure to high temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polymeric build material is exposed to high temperatures for prolonged periods during 3D printing, then material coalescence and fusing are achieved, but thermal degradation and oxidation occur leading to discoloration and reduced recyclability

Engineering Contradiction:

Improvematerial coalescenceVSAvoidthermal degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies oxygen plasma treatment to intentionally introduce controlled oxidation and create oxygen-containing functional groups on the build material surface. This converts the harmful oxidation effect into a beneficial surface modification that improves layer adhesion and coalescence, while the stabilizer minimizes unwanted discoloration during the thermal process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent introduces a stabilizer as an intermediary substance that is applied to the build material before printing. This stabilizer acts as a protective mediator during the thermal printing process, reducing oxidation and thermal degradation of the polymeric material while allowing the necessary coalescence to occur

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If build material is pre-heated to reduce thermal degradation, then exposure time to high temperatures is reduced, but energy consumption increases

Engineering Contradiction:

Improvethermal degradationVSAvoidenergy consumption

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

The patent applies oxygen plasma treatment and stabilizer application as preliminary actions before the main thermal printing process. These pre-treatments prepare the build material surface to improve coalescence and protect against degradation, allowing the thermal process to proceed more efficiently with potentially reduced overall energy consumption

Inventive Principle:

Principle #10Preliminary action

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 use of the detailing agent reduces thermal degradation, improves the mechanical strength and aesthetic appeal of the 3D objects, and enhances the recyclability of the polymeric build material by minimizing discoloration and chain scission.

Implementation Method 1

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

the fusing agent is capable of absorbing radiation and converting the absorbed radiation to thermal energy, which in turn fuses/coalesces the polymeric build material

Methodology Applied

Scientific EffectAbsorption of radiation: Absorption (EM radiation)

Data Source

PatentUS11426932B2Three-dimensional printing

Publication Date: 2022.08.30 PERIDOT PRINT LLC

AI summary

In an example of a method for reducing oxidation of a build material during three-dimensional printing, a portion of a layer of a polymeric build material is patterned by selectively applying a fusing agent on the portion. A detailing agent selectively applied on a non-patterned portion of the layer. The detailing agent includes a stabilizer to reduce oxidation of the polymeric build material. The layer is exposed to electromagnetic radiation to fuse the portion to form a 3D object layer. The stabilizer at least minimizes discoloration of the non-patterned portion.