Removable Binders for Complex 3D Printed Geometries
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Solution Overview
Problem
Conventional 3D printing methods face challenges in creating three-dimensional articles with complex geometries and fragile components, as they often require support structures that can cause deformation or fracture, and lack flexibility in printing materials with specific mechanical and thermal properties.
Innovation Solution
The method involves depositing a powder layer on a build plate and using both a permanent and a removable binding agent, where the permanent agent polymerizes to form the final polymer and the removable agent is selectively applied and later removed, allowing for the creation of complex geometries and fragile components without deformation, and enabling better mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If support structures are used in conventional 3D printing to enable complex geometries and overhanging parts, then the ability to print complex geometries is improved, but the risk of deformation or fracture during printing increases
Solution Approach 1:
The binding agent is segmented into two distinct types: a permanent binding agent that forms the final structural polymer, and a removable binding agent that forms temporary support structures. This segmentation allows the support structures to be differentiated from the final product, enabling their removal after printing without damaging the permanent structure.
Solution Approach 2:
The removable binding agent is applied in advance to create temporary support structures before the permanent structure is fully formed. These preliminary support structures enable the printing of overhanging and complex geometries, and are subsequently removed to reveal the final product without the supports.
2Strength
If conventional binding agents are used that remain permanent, then structural integrity is improved, but flexibility in material selection and property tuning is reduced
Solution Approach 1:
The binding agent system is divided into two functional components with different roles: one component (permanent binding agent) provides structural integrity, while the other (removable binding agent) provides temporary support and is later eliminated. This allows independent optimization of each component's properties.
Solution Approach 2:
The patent enables independent tuning of parameters for each binding agent type, including polymerization conditions, mechanical properties, thermal characteristics, and removal mechanisms. This parameter independence provides flexibility in selecting materials with specific properties for each function.
3Device complexity
If a single binding agent is used for both structural formation and support, then process simplicity is improved, but the ability to create fragile components without deformation is reduced
Solution Approach 1:
The single binding agent is segmented into two types with differentiated functions and removal characteristics. The removable binding agent can be selectively eliminated after serving its support function, allowing fragile components to be printed with temporary support and then released without deformation.
Solution Approach 2:
The removable binding agent acts as an intermediary material that facilitates the printing of fragile components by providing temporary support during the printing process, then being removed to leave the final product without the intermediary material causing deformation or fracture.
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 rapid production of three-dimensional articles with improved mechanical and thermal properties, allowing for the printing of thin or fragile components and complex geometries, while avoiding deformation and fracture, and providing flexibility in material selection.
Implementation Method 1
exposing the printed solution to a stimulus to form a polymer layer of the three-dimensional article
Implementation Method 2
a liquid or a colloidal binder material to layers of a powdered build material... the binder infiltrates the material and reacts with the powder, causing the layer to solidify... by, for example, activating an adhesive in the powder
Data Source
AI summary
The present invention provides methods, processes, and systems for the manufacture of three-dimensional articles made of polymers using 3D printing. A layer of prepolymer is deposited on a build plate to form a powder bed. Then, solutions of first and/or second binding agents are printed on the powder bed in a predetermined pattern. After a predetermined period of time, sequential layers are printed to provide the three-dimensional article. The removable binding agent is then removed. The three-dimensional object can be cured to produce the three-dimensional article composed of the final polymers.