3D Printed Rubber Structures Using High Mooney Viscosity Powders
Solution Overview
Problem
Current 3D printing technologies cannot effectively work with ultra-high viscosity materials at room temperature, which are needed to produce durable, high-strength three-dimensional structures with high elasticity and stability, especially in diversified geometries and dimensions below 1 mm, without phase change and maintaining shape stability.
Innovation Solution
A process involving the application and curing of at least two layers of materials with high Mooney viscosity (>10 ME at 60°C and <200 ME at 100°C) as powders, without phase transition, to form a temperature-stable, rubbery three-dimensional structure with enhanced mechanical stability and elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultra-high viscosity materials are used to produce durable, high-strength three-dimensional structures, then the strength and elasticity of the structure are improved, but the materials cannot be effectively processed at room temperature without phase change
Solution Approach 1:
The patent applies parameter changes by heating the ultra-high viscosity materials above their glass transition temperature (Tg) during processing. This temperature parameter change reduces the viscosity of the materials, enabling them to be effectively deposited and shaped while maintaining their ultra-high viscosity characteristics at room temperature for final structural integrity.
2Stability of the object's composition
If materials are processed without phase change to maintain shape stability, then the shape integrity is improved, but the materials become difficult to process at room temperature
Solution Approach 1:
The patent utilizes temporary parameter changes by raising the temperature above Tg during the deposition process to enable material flow and shaping, then allowing the material to return to its stable, shape-retaining state at room temperature after deposition. This controlled parameter change enables both processability and shape stability.
3Strength
If high Mooney viscosity materials (>10 ME at 60°C) are used to achieve high elasticity and stability, then the mechanical properties are improved, but the materials cannot be handled as powder during 3D printing
Solution Approach 1:
The patent applies parameter changes by controlling the temperature during the 3D printing process to be above the glass transition temperature of the rubber materials. This temperature parameter change transforms the materials from a rigid, unprocessable state to a viscous, handleable state that can be effectively deposited as powder or granular material, while maintaining the desired high elasticity and mechanical stability in the final cured product.
4Ease of manufacture
If thermoplastic materials are extruded at high temperatures (185°C to above 400°C), then the materials can be processed, but the process focuses on liquifying materials rather than working with ultra-high viscosity materials
Solution Approach 1:
The patent applies parameter changes by operating at a lower temperature range (above Tg but below traditional thermoplastic processing temperatures) and utilizing the viscoelastic properties of rubber materials. This enables processing of ultra-high viscosity materials without complete liquification, expanding the versatility of 3D printing beyond conventional thermoplastics to include rubber materials with unique mechanical properties.
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
Enables the production of durable, high-strength three-dimensional structures with high elasticity and stability, maintaining shape integrity across various temperatures and dimensions, and extending shelf-life for at least one year with minimal dimensional change.
Implementation Method 1
curing the materials, wherein at least one of the materials has a Mooney viscosity of >10 ME at 60° C.
Implementation Method 2
produce a three dimensional structure in diversified geometries which provide a high elasticity combined with a high stability, a high tensile strength or a high elongation before break
Data Source
AI summary
A process is described for producing a three dimensional structure, the process including the following steps a) applying of at least a first material M1 onto a substrate to build a first layer L1 on the substrate; b) layering of at least one further layer Ly of the first material M1 or of a further material Mx onto the first layer L1, wherein the at least one further layer Ly covers the first layer L1 and/or previous layer Ly−1 at least partially to build a precursor of the three dimensional structure; c) curing the precursor to achieve the three dimensional structure; wherein at least one of the materials M1 or Mx provides a Mooney viscosity of >10 ME at 60° C. and of <200 ME at 100° C. before curing and wherein at least one of the first material Mi or of the further material Mx is a powder. Also, a three dimensional structure is described which is available according to the process according to the invention.