3D Printing Semi-Crystalline Polymer Surface Energy Treatment

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Solution Overview

Problem

Existing 3D printing techniques face challenges in producing mechanically strong and aesthetically pleasing objects due to issues with polymeric build materials, such as insufficient wetting among melted particles and a higher affinity to non-melted particles, leading to non-uniform coalescence and shape defects.

Innovation Solution

A build material composition with a semi-crystalline thermoplastic polymer having a surface energy density greater than 41 mN/m, achieved through plasma or solution treatment, which enhances the polymer's hydrophilicity and wetting properties, leading to improved coalescence and reduced shape defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional polymeric build materials are used in 3D printing, then the printing process can be completed, but the melted particles do not wet each other uniformly and have higher affinity to non-melted particles, resulting in non-uniform coalescence and shape defects

Engineering Contradiction:

Improvecoalescence uniformityVSAvoidshape accuracy

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies surface treatment (plasma or solution treatment) to change the surface energy parameters of the polymeric build material particles. This modifies the surface chemistry to enhance wetting characteristics during melting, ensuring uniform coalescence. The treatment alters surface energy density and contact angle parameters to prevent shape defects and improve dimensional accuracy of printed objects.

Inventive Principle:

Principle #35Parameter changes

2Strength

If the polymeric build material particles are melted for coalescence, then material bonding is achieved, but insufficient wetting among melted particles leads to non-uniform coalescence

Engineering Contradiction:

Improvematerial bondingVSAvoidcoalescence uniformity

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Surface treatment modifies the thermal and surface energy parameters of the polymeric particles to improve wetting behavior during the melting phase. This ensures that when particles are heated for coalescence, they wet each other uniformly, creating consistent material bonding throughout the printed structure without localized weak spots or non-uniform regions.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional polymeric build materials are used, then the printing process proceeds, but the particles have higher affinity to non-melted particles, causing shape defects

Engineering Contradiction:

Improveprinting process continuityVSAvoidshape accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The surface treatment permanently modifies the surface energy parameters of the polymeric particles, creating a consistent affinity profile that prevents preferential bonding to non-melted particles. This parameter change maintains printing process continuity while eliminating shape defects caused by non-uniform particle interactions during the printing cycle.

Inventive Principle:

Principle #35Parameter changes

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 treated semi-crystalline thermoplastic polymers exhibit improved compatibility with 3D printing processes, resulting in the formation of mechanically strong and aesthetically pleasing 3D objects with faster consolidation rates and smoother surfaces.

Implementation Method 1

Methodology Applied

Scientific EffectPlasma treatment: Plasma

Implementation Method 2

achieved through plasma or solution treatment, which enhances the polymer's hydrophilicity and wetting properties

Methodology Applied

Scientific EffectSurface treatment: Surface Tension

Implementation Method 3

a fusing agent to be applied to at least a portion of the build material composition during 3D printing, the fusing agent including an energy absorber to absorb electromagnetic radiation to coalesce the semi-crystalline thermoplastic polymer

Methodology Applied

Scientific EffectElectromagnetic radiation absorption: Absorption (EM radiation)

Implementation Method 4

the fusing agent including an energy absorber to absorb electromagnetic radiation to coalesce the semi-crystalline thermoplastic polymer

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS20250034333A1Three-dimensional printing

Publication Date: 2025.01.30 PERIDOT PRINT LLC

AI summary

An example of a three-dimensional (3D) printing kit includes a build material composition and a fusing agent to be applied to at least a portion of the build material composition during 3D printing. The build material composition includes a semi-crystalline thermoplastic polymer having a surface energy density greater than 41 mN/m. The fusing agent includes an energy absorber to absorb electromagnetic radiation to coalesce the semi-crystalline thermoplastic polymer in the at least the portion.