Polymeric Filament Adhesion in Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing processes face challenges in achieving sufficient adhesion between build materials and substrates, leading to defects such as shape deviation and detachment during the formation and removal of 3D objects, which can result in damaged objects or substrates.
Innovation Solution
The use of polymeric materials comprising units of a diacid component and a glycol component, derived from specific acids and glycols, which are extruded to form a filament that can be deposited layer-by-layer onto a substrate with improved viscosity, melt stability, and adhesion properties, minimizing clogging and degradation, and enhancing the bonding between layers and the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional build materials are used in additive manufacturing, then the manufacturing process can be performed, but insufficient adhesion between build material and substrate occurs leading to shape deviation and detachment
Solution Approach 1:
The patent modifies the chemical composition parameters of the build material by incorporating specific functional groups (carboxyl, hydroxyl, amine) that enhance chemical bonding capability with the substrate, thereby improving adhesion strength and reducing shape deviation during the additive manufacturing process
Solution Approach 2:
The patent employs composite polymeric materials combining multiple functional components including adhesion promoters, crosslinking agents, and base polymers to achieve superior bonding characteristics between the build material and substrate, preventing detachment and maintaining dimensional accuracy
2Ease of manufacture
If build material is deposited layer-by-layer onto substrate, then 3D objects can be formed, but defects such as detachment occur during object removal
Solution Approach 1:
The patent applies different functional properties to different regions of the build material - the interface region with the substrate contains higher concentrations of adhesion-promoting functional groups, while other regions maintain standard polymeric properties, ensuring strong bonding where needed without compromising overall object integrity during removal
Solution Approach 2:
The patent incorporates adhesion promoters and coupling agents into the build material composition before deposition, pre-establishing strong chemical bonds between the material and substrate that prevent detachment during the object removal process
3Productivity
If polymeric material is extruded to form filament, then the material can be deposited, but clogging and degradation occur due to viscosity and melt stability issues
Solution Approach 1:
The patent optimizes the molecular weight distribution and incorporates plasticizers or lubricants into the polymeric material composition to reduce melt viscosity and improve flow characteristics, enabling smooth extrusion at higher rates without clogging while maintaining material stability
Solution Approach 2:
The patent uses readily processable polymeric materials with optimized rheological properties that can be extruded efficiently as single-use filaments, accepting some material degradation in exchange for high productivity and consistent extrusion performance
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 results in reduced defects by ensuring strong adhesion between the build material and the substrate, allowing for the successful formation and removal of 3D objects with minimal damage, while maintaining the mechanical properties of the polymeric material throughout the additive manufacturing process.
Implementation Method 1
additive manufacturing can be performed by extruding a material through a nozzle and depositing (typically layer-by-layer) the material onto a substrate to form an object
Implementation Method 2
The build material from which the object is formed hardens shortly after extrusion to form a solid 3D object
Data Source
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AI summary
Objects can be produced using an additive manufacturing process and the objects can be removed from the substrates on which the objects are formed. An object can include a plurality of layers of a polymeric material that includes units of a diacid component and units of a glycol component. A process can be used to form the object that includes depositing a plurality of layers of the polymeric material onto a substrate to form the object. In some cases, the plurality of layers are deposited onto the substrate according to a predetermined design.