Resin Powder Melt Flow Stability for 3D Printing
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Solution Overview
Problem
Recycled resin powders for solid freeform fabrication often result in surface deficiencies such as orange peel, voids, and degradation of tensile strength due to changes in melt mass-flow rate and cross-linking or decomposition during the fabrication process.
Innovation Solution
A resin powder with a melting point of 100 degrees C. or higher and a melt mass-flow rate ratio of 0.80 to 1.20, measured under specific conditions, is developed to maintain stability and prevent surface deficiencies and strength deterioration, regardless of whether the powder is fresh or recycled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resin powder is reused after fabrication, then productivity is improved through material recycling, but manufacturing precision deteriorates due to surface deficiencies like orange peel and voids
Solution Approach 1:
The patent changes the chemical composition parameters of the resin powder by adding specific additives (silane-modified polyethylene in 0.1-5 wt%, hydroxyl-terminated polybutadiene in 0.1-5 wt%, and titanium dioxide in 0.1-5 wt%) to stabilize the melt mass-flow rate and prevent cross-linking decomposition, thereby maintaining surface quality during recycling
Solution Approach 2:
The patent applies preliminary action by pre-treating the resin powder with stabilizing additives before recycling occurs, preventing cross-linking and decomposition that would otherwise cause surface deficiencies during subsequent fabrication processes
2Manufacturing precision
If resin powder is irradiated with laser beams for melting and sintering, then manufacturing precision is improved through selective fusion, but reliability deteriorates due to cross-linking and decomposition of the resin
Solution Approach 1:
The patent introduces intermediary substances (silane-modified polyethylene and hydroxyl-terminated polybutadiene) that act as mediators between the laser irradiation and the resin powder, absorbing excess energy and preventing direct thermal degradation and cross-linking of the resin structure
Solution Approach 2:
The patent changes the thermal and chemical parameters of the resin system by incorporating additives that modify the melting behavior and thermal stability, allowing laser sintering to proceed without causing cross-linking decomposition
3Productivity
If the melt mass-flow rate of resin powder changes during fabrication, then productivity is improved through process flexibility, but manufacturing precision deteriorates due to inconsistent material flow
Solution Approach 1:
The patent establishes a feedback mechanism where the melt mass-flow rate is monitored and controlled through the presence of specific additives that stabilize the flow characteristics, ensuring consistent material delivery despite process variations
Solution Approach 2:
The patent changes the rheological parameters of the resin powder by adding modifiers that stabilize the melt mass-flow rate, maintaining consistent material flow properties throughout the fabrication process
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 effectively prevents surface deficiencies and tensile strength degradation, ensuring high-quality fabrication objects with improved recyclability and mechanical performance.
Implementation Method 1
a thin layer of resin powder is irradiated with laser beams to selectively melt and sinter the resin powder
Implementation Method 2
the resin powder is heated to temperatures not lower than the softening point and melted
Implementation Method 3
the resin powder is irradiated with infrared rays to selectively melt the resin powder
Data Source
AI summary
A resin powder for solid freeform fabrication, having a melting point of 100 degrees C. or higher as measured according to ISO 3146 regulation and a ratio of melt mass-flow rate B to melt mass-flow rate A of greater than 0.80 to 1.20, wherein the melt mass-flow rate A and the melt mass-flow rate B are respectively measured at 15 degrees C. higher than the melting point under a load of 2.16 kg according to JIS K7210 format before and after the resin powder is maintained at a temperature 15 degrees C. lower than the melting point under a pressure of 0.1 kPa for four hours.