Additive Manufacturing Powder Coating for Binder Infiltration
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Solution Overview
Problem
In the binder-jet additive manufacturing method, the use of water-based binder solutions often results in slow infiltration into the powder layer, leading to decreased production speed and surface accuracy due to varying infiltration rates and speeds.
Innovation Solution
The use of an additive manufacturing powder with a metal particle surface coated with a compound derived from a coupling agent containing an amino group or an epoxy group, which enhances the infiltration rate of a water-based binder solution, ensuring it penetrates the powder layer within 10 seconds or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a water-based binder solution is used in the binder-jet method, then the binder solution can be easily supplied and ejected, but the infiltration speed into the powder layer becomes slow and uneven
Solution Approach 1:
The patent applies parameter changes by modifying the surface properties of metal particles through coating with coupling agents containing amino groups or epoxy groups. This chemical modification changes the surface energy and wettability parameters, enabling water-based binder solutions to infiltrate the powder layer rapidly (within 10 seconds) while maintaining ease of supply through standard inkjet equipment.
2Ease of manufacture
If a water-based binder solution is used, then the binder solution can be readily prepared and applied, but the production speed decreases due to slow infiltration
Solution Approach 1:
The patent modifies the surface parameters of metal particles by applying coupling agent coatings, which fundamentally changes the infiltration kinetics. This allows water-based binder solutions to maintain their ease of preparation and application while achieving rapid infiltration (≤10 seconds), thereby resolving the productivity bottleneck without sacrificing manufacturing simplicity.
3Ease of operation
If a water-based binder solution is used, then the binder solution can be easily handled, but the surface accuracy decreases due to uneven infiltration range
Solution Approach 1:
The patent applies surface modification through coupling agent coating, which changes the surface energy parameters of metal particles. This creates uniform wettability across the powder layer surface, enabling water-based binder solutions to infiltrate evenly and consistently. The result is improved surface accuracy and uniform infiltration ranges while maintaining the ease of handling associated with water-based solutions.
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 configuration allows for efficient production of additively manufactured bodies with high surface accuracy and increased production speed by ensuring rapid and uniform infiltration of the binder solution, preventing surface defects and speed reductions.
Implementation Method 1
a coating film provided at a surface of the metal particle and containing a compound derived from a coupling agent containing an amino group or an epoxy group
Implementation Method 2
a coating film provided at a surface of the metal particle and containing a compound derived from a coupling agent containing an amino group or an epoxy group
Implementation Method 3
When 40 μL of water is dropped onto a powder layer formed by compressing to have a relative density of 51%, a time for the water to infiltrate is 10.00 seconds or shorter
Data Source
AI summary
An additive manufacturing powder used for producing an additively manufactured body by a binder-jet method includes a metal particle and a coating film provided at a surface of the metal particle and containing a compound derived from a coupling agent containing an amino group or an epoxy group. When 40 μL of water is dropped onto a powder layer formed by compressing to have a relative density of 51%, a time for the water to infiltrate is 10.00 seconds or shorter.