Reactive Composition Additive Manufacturing with Mixer-Controlled Viscosity
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Solution Overview
Problem
Existing additive manufacturing methods using coreactive components face challenges in controlling the reaction rate and viscosity of reactive materials, leading to issues such as nozzle clogging and unsuitable deposition properties for building strong and complex objects.
Innovation Solution
A method involving the controlled deposition of coreactive compositions, where two reactive components are pumped through a mixer and extruded as a coreactive composition, forming extrudates that can be used to create objects by successively depositing layers, allowing for covalent bonding between layers and rapid curing without the need for heat control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If coreactive components are used in additive manufacturing, then interlayer bonding strength is improved, but viscosity control becomes difficult leading to nozzle clogging
Solution Approach 1:
The coreactive composition is divided into two separate components that are stored and delivered independently through separate pumps. This segmentation allows each component to maintain its own viscosity characteristics without the complications of a fully mixed reactive system, preventing nozzle clogging while enabling strong interlayer bonding when the components are combined at the deposition point.
Solution Approach 2:
A mixer is introduced as an intermediary device between the component delivery system and the deposition nozzle. The mixer combines the two coreactive components in a controlled manner, allowing the reaction to occur after mixing but before deposition. This intermediary approach enables viscosity control during delivery while maintaining the reactive bonding capability.
2Productivity
If reactive materials are used for rapid curing, then printing speed is improved, but reaction rate control becomes difficult
Solution Approach 1:
The two components are prepared and delivered in a pre-mixed ratio through the pumping system, but the actual chemical reaction is delayed until after mixing and just before deposition. This preliminary preparation allows the system to maintain rapid curing capability while controlling the reaction rate through the timing and conditions of the mixing and deposition process, rather than having the reaction start immediately upon contact.
Solution Approach 2:
The system dynamically controls the reaction process by adjusting the mixing conditions, residence time in the mixer, and deposition timing. This dynamic approach allows optimization of both printing speed and reaction rate control, enabling rapid curing when needed while preventing premature or uncontrolled reactions that would hinder manufacturability.
3Manufacturing precision
If two component pumping system is implemented, then composition control is improved, but device complexity increases
Solution Approach 1:
The dual pump system is designed with both pumps and the mixer integrated into a single coordinated unit that can be controlled through a unified system. This multi-functional design allows the pumping system to perform multiple functions (precise metering, mixing, and delivery) while reducing overall complexity compared to having completely separate systems for each function. The system achieves improved composition control through this integrated approach.
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 enables the production of stronger, faster-printed objects with improved mechanical and electrical properties, such as solvent resistance and thermal conductivity, by utilizing coreactive components like polyisocyanates and polyamines that react rapidly at room temperature, facilitating high deposition speeds and controlled viscosity.
Implementation Method 1
the first compound is reactive with the second compound
Implementation Method 2
allowing for covalent bonding between layers
Data Source
AI summary
Methods of additive manufacture using coreactive components are disclosed. Thermosetting compositions for additive manufacturing are also disclosed.