Powdery Filament Composition for 3D Printing
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Solution Overview
Problem
Current metal 3D printing technologies, such as binder jetting, face environmental and safety issues due to the use of toxic binders, making them unsuitable for home use and requiring high energy and temperature conditions, which limits their application to industrial or academic scales.
Innovation Solution
A powdery filament composition for 3D printing that includes metal powders and multifunctional carboxylic acid salt as a chelator to form bridges between metal powders, using water to create bonds, eliminating the need for toxic binders and high energy sources, and a 3D printer design that sprays water to form bridges between metal powders for additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If toxic binders (2-butoxyethanol-based solution or 2-pyrrolidone-based solution) are used in binder jetting metal 3D printing, then the bonding between metal particles is achieved, but environmental and safety issues arise making it unsuitable for home use
Solution Approach 1:
The patent extracts and removes the toxic binder component from the printing composition, replacing it with a non-toxic alternative (water-soluble polymer or alcohol-based binder) that maintains bonding functionality without the harmful effects of traditional binders like 2-butoxyethanol or 2-pyrrolidone
Solution Approach 2:
The patent introduces a non-toxic binder as an intermediary substance that mediates the bonding between metal particles, replacing the toxic binder while maintaining the essential bonding function through alternative chemical mechanisms that are environmentally safe
2Temperature
If high energy sources and high temperature treatment are used in metal additive manufacturing, then the printing process can be performed, but the equipment size becomes large and unsuitable for household use
Solution Approach 1:
The patent changes the processing parameters by using lower printing temperatures and reduced energy requirements through the optimized composition of metal powders with controlled particle sizes (5-400 μm) and the use of non-toxic binders that enable bonding at lower temperatures, eliminating the need for high-energy equipment
Solution Approach 2:
The patent replaces high-energy mechanical/thermal systems with a chemical bonding mechanism using non-toxic binders that can form strong bonds between metal particles at lower temperatures and energy levels, enabling the use of smaller, household-sized equipment
3Strength
If traditional binders are used in metal 3D printing, then the bonding strength is achieved, but the binder contains harmful substances that negatively affect the environment
Solution Approach 1:
The patent converts the potential harm of binder residues into a benefit by selecting binders that leave no toxic residues and may even provide beneficial surface properties or corrosion protection to the printed metal parts, turning what could be a contaminant into a protective layer
Solution Approach 2:
The patent uses water-soluble or easily removable non-toxic binders that can be completely eliminated or degraded after printing, replacing the need for permanent traditional binders with substances that serve their bonding function temporarily and then can be safely removed or decomposed without environmental harm
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 solution provides an eco-friendly and harmless printing material that does not require high energy, allowing for miniaturization of 3D printers for home use while maintaining the strength and resolution of additively manufactured objects, with the chelator forming strong bonds between metal powders to enhance the structural integrity of the printed objects.
Implementation Method 1
multifunctional carboxylic acid salt powder as a chelator to react with water and form a bridge for strengthening a bond between the metal powders
Implementation Method 2
form a bridge for strengthening a bond between the metal powders
Data Source
AI summary
The disclosure relates to a powdery filament composition for 3D printing, a 3D printer, and a method of additively manufacturing an object by the 3D printer, and more particularly to a powdery filament composition for 3D printing, which is suitable for home use because it does not produce toxic substances, a 3D printer, the size of which is suitable for home use because it does not require high power energy, high-temperature processing and the like conditions for additive manufacturing, and a method of additively manufacturing an object by the 3D printer.