Preceramic Polymer Binders for Binder Jet 3D Printing
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Solution Overview
Problem
Current binder jet 3D printing (BJ3DP) methods for ceramics face challenges with weak and fragile parts after binder burnout, requiring extensive post-processing for densification, which is time-consuming and costly.
Innovation Solution
A binder jet 3D printing process using a binder composition comprising preceramic polymers, which are cured and pyrolyzed to form strong green and brown parts, followed by polymer impregnation and pyrolysis to densify the ceramic parts, reducing the need for additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional binders are used in binder jet 3D printing for ceramics, then the binder can be removed by burning out, but the resulting brown parts are very weak and difficult to transport
Solution Approach 1:
The patent changes the chemical composition parameters of the binder from conventional organic binders to preceramic polymers. This parameter change allows the binder to transform into a ceramic material during pyrolysis, providing structural support to the brown parts and significantly improving their strength while still allowing for binder removal through controlled pyrolysis processes
Solution Approach 2:
The patent uses preceramic polymers as composite binder materials that combine the properties of organic binders (ease of application and removal) with ceramic properties (strength and structural integrity). The preceramic polymer binder forms a composite structure with the ceramic powder, where the binder serves dual functions: binding the powder during printing and providing structural support after binder removal through pyrolysis
2Manufacturing precision
If extensive post-processing for densification is performed on ceramic parts, then densification is achieved, but the process becomes time-consuming and costly
Solution Approach 1:
The patent performs preliminary densification action during the binder jet printing process itself by using preceramic polymer binders that contribute to densification during pyrolysis. This preliminary action reduces the extent of subsequent densification processing needed, thereby reducing post-processing time and cost while still achieving the required manufacturing precision
Solution Approach 2:
The patent merges the binder removal process with the densification process by using preceramic polymers that transform into ceramic material during pyrolysis. This merging combines two separate processes (binder removal and densification) into one integrated pyrolysis step, reducing the number of processing steps and overall processing time while achieving both binder removal and densification objectives
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 process produces ceramic parts with high green strength and accelerated densification, resulting in stronger brown parts and reduced post-processing time and cost, while maintaining structural integrity.
Implementation Method 1
curing the binder to generate a green body part
Implementation Method 2
pyrolyzing the green body part into a brown part
Implementation Method 3
depositing a first binder composition comprising a printing binder into the layer of powder material
Data Source
AI summary
The present disclosure relates to a binder jet 3D process for preparing a ceramic part in which a binder composition is deposited on a powder material in a binder jet machine during which the binder in the binder composition comprises a preceramic polymer, and the binder impregnates particles of the powder.