Resin Powder for Solid Freeform Fabrication
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Solution Overview
Problem
Existing resin powders for solid freeform fabrication face challenges such as high inner stress between layers, poor recyclability, and decreased melt viscosity and flowability after initial use, leading to inefficient fabrication and waste.
Innovation Solution
The development of a resin powder with a 50 percent cumulative volume particle diameter of 5 to 100 μm and a volume average to number average particle diameter ratio of 2.50 or less, which satisfies specific conditions related to melting starting temperatures and crystallinity measured by differential scanning calorimetry and X-ray diffraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If resin powder is heated to temperatures close to the softening point to maintain low inner stress, then layer stress relaxation is improved, but heat contraction and energy consumption increase
Solution Approach 1:
The patent modifies the chemical composition parameters of the resin powder by incorporating specific additives (nucleating agents, plasticizers, and lubricants) that change the thermal and mechanical properties of the resin, allowing effective fabrication at lower temperatures
Solution Approach 2:
The patent creates a composite resin powder system by combining base resin with multiple functional additives, where each component contributes specific properties that collectively reduce both stress and energy consumption during fabrication
2Ease of manufacture
If conventional resin powder is used for solid freeform fabrication, then fabrication can be conducted, but dimension stability deteriorates due to high inner stress and heat contraction
Solution Approach 1:
The patent adjusts key parameters including particle size distribution (5-100 μm with specific D10, D50, D90 values), chemical composition ratios, and thermal properties to achieve optimal dimension stability while maintaining fabrication ease
Solution Approach 2:
The patent introduces lubricant additives as intermediary substances that mediate between the resin particles and heating process, reducing friction and heat contraction to improve dimension stability
3Loss of substance
If resin powder is reused after initial fabrication, then material utilization improves, but melt viscosity and flowability decrease leading to poor recyclability
Solution Approach 1:
The patent designs the resin powder with self-regenerating properties through specific chemical additives that maintain or restore melt flow characteristics after thermal processing, enabling the material to serve itself across multiple fabrication cycles
Solution Approach 2:
The patent modifies the thermal and rheological parameters of the resin through chemical composition control, ensuring that viscosity and flowability parameters remain within acceptable ranges even after repeated heating and cooling cycles
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 resin powder improves dimension stability, reduces waste, enhances recyclability, and maintains mechanical properties, allowing for the efficient fabrication of complex and fine solid freeform objects.
Implementation Method 1
the resin powder is heated to temperatures close to the softening point of the resin. Thereafter, the heated layer is selectively irradiated with laser beams to raise the temperature of the resin powder to the softening point or higher so that the resin powder is fused and attached to each other
Implementation Method 2
the heated layer is selectively irradiated with laser beams to raise the temperature of the resin powder to the softening point or higher
Implementation Method 3
the resin powder is fused and attached to each other to conduct solid freeform fabrication
Data Source
AI summary
A resin powder for solid freeform fabrication has a 50 percent cumulative volume particle diameter of from 5 to 100 μm and a ratio (Mv/Mn) of a volume average particle diameter (Mv) to the number average particle diameter (Mn) of 2.50 or less and satisfies at least one of the following conditions (1) to (3):(1): Tmf1>Tmf2 and (Tmf1−Tmf2)≥3 degrees C., both Tmf1 and Tmf2 are measured in differential scanning calorimetry measuring according to ISO 3146.(2): Cd1>Cd2 and (Cd1−Cd2)≥3 percent, both Cd1 and Cd2 are measured in differential scanning calorimetry measuring according to ISO 3146, and(3): C×1>C×2 and (C×1−C×2)≥3 percent.