Pulverulent Thermoplastic Polyurethane Blends for 3D Printing
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Solution Overview
Problem
Current powder-based 3D printing materials, such as polyamide 11 (PA11) and polyamide 12 (PA12), lack suitable physical properties and have an inadequate temperature window for all applications, limiting their versatility in additive manufacturing.
Innovation Solution
Development of pulverulent thermoplastic polymer blends based on semicrystalline aliphatic thermoplastic polyurethane (ATP) blended with thermoplastic polyurethane (TPU), which provides improved physical and thermal properties, including a broader temperature window and enhanced flexibility, by forming a microphase-separated structure with controlled phase separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If PA11 and PA12 are used as powder-based 3D printing materials, then sharp melting and crystallization temperatures are achieved, but the temperature window is not ideal and physical properties are limited for certain applications
Solution Approach 1:
The patent employs composite materials by creating blends of polyamide 11 and polyamide 12 in specific ratios (e.g., 70/30, 65/35, 60/40, 55/45, 50/50). This composite approach combines the sharp melting/crystallization characteristics of both materials to achieve an optimized temperature window while maintaining desirable physical properties for various applications.
Solution Approach 2:
The patent systematically varies the compositional parameters of the PA11/PA12 blends to optimize performance. By adjusting the weight ratios of the two polyamides and controlling processing parameters such as sintering temperature and layer thickness, the patent achieves a broader and more versatile temperature window that accommodates different application requirements.
2Strength
If PA11 and PA12 are used for powder-based 3D printing, then high heat and chemical resistance are achieved, but flexibility and water uptake properties do not meet all application requirements
Solution Approach 1:
The patent applies local quality by creating regions with different polyamide compositions within the printed part. By controlling the blend ratio and processing parameters, specific areas can exhibit enhanced flexibility or modified water uptake characteristics while maintaining overall structural integrity and heat resistance.
Solution Approach 2:
The PA11/PA12 blend creates a composite material system where the two polyamides complement each other's properties. PA11 contributes flexibility and lower water uptake, while PA12 provides dimensional stability and heat resistance, resulting in a material with balanced and tunable properties for diverse applications.
3Adaptability or versatility
If a broader temperature window is desired for additive manufacturing materials, then the sintering process becomes more complex, but material versatility improves
Solution Approach 1:
The patent employs partial action by using a blend composition that provides sufficient temperature window broadening without requiring extreme process modifications. The PA11/PA12 blend achieves an optimized temperature window that works effectively with conventional sintering equipment and processes, avoiding excessive complexity while delivering enhanced versatility.
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 ATP/TPU blends maintain comparable thermal properties to ATP while improving mechanical properties like tensile elongation and lowering crystallization temperature, offering a more versatile material for additive manufacturing with a wider sintering window and improved mechanical performance compared to PA11 and PA12.
Implementation Method 1
forming a microphase-separated structure with controlled phase separation
Implementation Method 2
Powder bed fusion techniques generally include depositing a layer of powder material that is selectively fused together, such as via thermal fusion
Implementation Method 3
a wider sintering window
Data Source
AI summary
The present disclosure is directed to pulverulent thermoplastic polymer blends comminuted to a particle size of less than 300 μm. The pulverulent thermoplastic polymer blends can include a first thermoplastic polyurethane and a second thermoplastic polyurethane at a weight ratio of from about 90:10 to about 30:70 first thermoplastic polyurethane to second thermoplastic polyurethane. The first thermoplastic polyurethane can include a reaction product of a first reaction mixture consisting of or consisting essentially of an aliphatic diisocyanate having a number average molecular weight of from 140 g/mol to 170 g/mol and an aliphatic diol having a number average molecular weight of from 62 g/mol to 120 g/mol. The second thermoplastic polyurethane can include a reaction product of a second reaction mixture comprising a polyisocyanate, an isocyanate-reactive component having a number average molecular weight of from 500 g/mol to 10,000 g/mol, and a chain extender having a number average molecular weight of from 60 g/mol to 450 g/mol.