Resin Powder for 3D Printing with Controlled Particle Size
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Solution Overview
Problem
Existing resin powders have high chargeability, leading to difficulties in handling and achieving desired properties in three-dimensional object production due to excessive attachment to handling members, resulting in suboptimal product quality.
Innovation Solution
A resin powder with a polyolefin-based resin having a melting point of 150 degrees C. or higher, a melt mass flow rate between 0.35 and 8.50 g/10 min, and a particle size distribution ratio of 1.35 or less, combined with external additives to enhance fluidity and prevent aggregation, improving handling and product properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If resin powder is used for three-dimensional object production, then object forming capability is achieved, but handling difficulty arises due to high chargeability and excessive attachment to handling members
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution (Dv/Dn ratio between 1.05 and 1.30) and surface properties of the resin powder particles. This optimization reduces chargeability and attachment to handling members while maintaining excellent fluidity and handleability during three-dimensional object production
Solution Approach 2:
The patent uses composite material approach by combining resin powder particles with specific surface treatments and additives that reduce electrostatic charge accumulation. The composite structure includes core resin particles with surface-modified layers that decrease harmful chargeability while preserving handling properties
2Manufacturing precision
If resin powder with high chargeability is used, then object forming is possible, but product quality deteriorates due to excessive attachment to handling members
Solution Approach 1:
The patent achieves high manufacturing precision by optimizing particle size distribution parameters (Dv/Dn ratio of 1.05-1.30) and controlling particle morphology. These parameter changes ensure uniform powder flow and layer formation, resulting in three-dimensional objects with high dimensional accuracy while minimizing attachment issues
3Manufacturing precision
If resin powder is used for three-dimensional object production, then object formation is achieved, but surface quality is suboptimal due to handling difficulties
Solution Approach 1:
The patent improves surface quality by precisely controlling particle size distribution (Dv/Dn ratio between 1.05 and 1.30) and particle circularity (0.94 or higher). These parameter optimizations enable smooth powder flow and uniform layer deposition, resulting in three-dimensional objects with excellent surface finish and quality
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 resin powder exhibits excellent fluidity and handleability, enabling the production of three-dimensional objects with high dimensional accuracy, strength, and surface quality, while reducing attachment to handling equipment and improving filling density.
Implementation Method 1
a laser beam irradiating unit configured to irradiate a laser beam to the powder layer
Implementation Method 2
The melting point of the resin powder is 150 degrees C. or higher
Implementation Method 3
a laser beam irradiating unit configured to irradiate a laser beam to the powder layer
Implementation Method 4
The melting point of the resin powder is 150 degrees C. or higher
Data Source
AI summary
Provided is a resin powder including a polyolefin-based resin, wherein a melting point of the resin powder is 150 degrees C. or higher, wherein a melt mass flow rate (MFR) of the resin powder measured according to JIS K 7210 is 0.35 (g/10 min) or greater but 8.50 (g/10 min) or less, and wherein a particle size distribution (volume average particle diameter Dv/number average particle diameter Dn) of the resin powder is 1.35 or less. In preferred embodiments, an average circularity of the resin powder is 0.975 or greater, and the polyolefin-based resin is a block copolymerized polypropylene resin.