SAN-Polyamide 3D Printing Molding Composition
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Solution Overview
Problem
Existing 3D printing materials, such as amorphous thermoplastics like ABS, are often too brittle and have high viscosity, making them unsuitable for complex shapes with bridging features like stairs and bridges, and they also emit unpleasant odors.
Innovation Solution
A thermoplastic molding composition comprising 35-60% impact-modified styrene-acrylonitrile copolymer, 33-58% polyamide, 1-10% styrene-acrylonitrile-maleic anhydride terpolymer, and 0.01-5% auxiliaries, with a specific molecular weight and viscosity range, optimized for low odor and improved toughness and viscosity ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If amorphous thermoplastics like ABS are used for 3D printing, then the material can be processed by melting and extruding, but the material is too brittle and has high viscosity
Solution Approach 1:
The patent uses a composite material system consisting of SAN copolymer matrix combined with specific rubber graft copolymers as impact modifiers. This composite structure allows the material to maintain processability while significantly improving toughness through the rubber phase that absorbs impact energy and prevents brittle failure.
Solution Approach 2:
The patent optimizes the molecular weight parameters of both the SAN copolymer and the rubber graft copolymer components. By carefully controlling the molecular weight ranges and their ratios, the material achieves an optimal balance between viscosity for extrusion processing and toughness for structural integrity, resolving the contradiction between ease of manufacture and strength.
2Productivity
If traditional 3D printing materials are used, then printing can be performed, but the viscosity is too high for complex shapes with bridging
Solution Approach 1:
The patent modifies the viscosity parameter by selecting specific molecular weight ranges for the SAN copolymer and rubber graft copolymer components. The controlled molecular weight reduction lowers the melt viscosity to a range that enables successful extrusion and deposition of complex geometries including bridges and overhangs, while maintaining adequate structural properties.
3Ease of manufacture
If conventional materials are used for 3D printing, then the process can proceed, but unpleasant odors are emitted
Solution Approach 1:
The patent changes the chemical composition parameters by using SAN copolymer instead of traditional ABS, and by carefully selecting the rubber graft copolymer components. This compositional change reduces the emission of unpleasant odors during the printing process while maintaining the thermoplastic processing characteristics needed for extrusion and layer-by-layer fabrication.
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 composition provides improved toughness and reduced viscosity, enabling successful 3D printing of complex shapes with good bridging quality and low odor, suitable for home and industrial use.
Implementation Method 1
the material is first liquefied and extruded, several layers of the material are applied to a carrier while moving, and then the shaped material is solidified by cooling below the solidification temperature of the material
Implementation Method 2
the liquefied molding composition by extrusion with a heating nozzle which is freely movable in the production plane in layers on a movable one Construction platform
Implementation Method 3
several layers of the material are applied to a carrier while moving, and then the shaped material is solidified by cooling below the solidification temperature of the material
Data Source
Figure 1
AI summary
The invention relates to the use of a thermoplastic moulding compound for 3D Printing, made of a mixture of the following components A - E: A: 35 - 60 wt.% impact resistant modified polymer A comprising: 30 - 95 wt.% SAN-copolymer and 5 - 70 wt.% ABS-graft copolymer; B: 33 - 58 wt.% aliphatic polyamide B; C: 1 -10 wt.% SANMSA-terpolymer C as a compatibilizing agent; D: 0.01 - 5 wt.% processing agent D; and E: 0 - 30 wt.% other additives E.