Sinterable Particles With Polymeric Coating for 3D Printing Green Strength
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Solution Overview
Problem
The 3D printing process using Powder Bed and Inkjet head (3DP) faces challenges in achieving high Green Strength for delicate structures, which is critical for producing complex geometries without compromising the quality of the final product, and existing methods fail to enhance Green Strength without altering the manufacturing process or affecting inkjet head performance.
Innovation Solution
The use of sinterable particles with a polymeric coating that can be removed via heat or solvent treatment, allowing for increased binder composition application to enhance Green Strength, while maintaining the existing manufacturing process and preventing surface reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the amount of binder composition is increased to enhance Green Strength, then the Green Strength improves, but the viscosity of the binder composition increases causing problems with inkjet head performance
Solution Approach 1:
The polymeric coating is applied to the particles in advance before the binding step. This preliminary action allows the particles to be pre-prepared with a coating that will enhance Green Strength when binder is applied, without requiring the binder itself to have high viscosity. The coating is deposited on particles prior to inkjet printing, enabling subsequent binder application at normal viscosities.
Solution Approach 2:
The polymeric coating acts as an intermediary between the particles and the binder composition. It provides a surface that enhances Green Strength when the binder is applied, but does not interfere with the inkjet head's ability to deposit the binder at appropriate viscosities. The coating mediates the interaction between particles and binder to achieve high Green Strength without compromising printing performance.
2Stability of the object's composition
If the Green Strength is increased to produce delicate structures, then the stability of green part improves, but the manufacturing process complexity increases
Solution Approach 1:
The invention changes the surface parameter of the particles by adding a polymeric coating. This parameter change (surface coating) provides enhanced Green Strength and stability for delicate structures, while maintaining compatibility with existing inkjet printing and sintering processes. The coating concentration and type can be adjusted to optimize performance without fundamentally altering the manufacturing workflow.
3Strength
If a polymeric coating is added to increase Green Strength, then the Green Strength improves, but the process complexity increases due to additional coating step
Solution Approach 1:
The polymeric coating is applied as a preliminary step before the main inkjet printing process. By preparing the coated particles in advance, the actual 3D printing process using existing inkjet equipment remains unchanged. The coating step can be performed separately using simple mixing or coating equipment, avoiding the need to modify complex inkjet printing systems.
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 approach significantly increases the Green Strength of the green part to levels unattainable with non-coated particles, enabling the production of more complex structures with improved stability and quality without requiring changes to the 3DP process or equipment.
Implementation Method 1
the green part is then subjected to a step of removing the binder component (so-called 'debinding'), which is typically effected by heat treatment leading to thermal decomposition or evaporation of the binder component
Implementation Method 2
heat treatment leading to thermal decomposition or evaporation of the binder component
Implementation Method 3
heat is applied on the platform in order to evaporate the solvent (typically water or another low temperature-boiling solvent, such as methanol, ethanol, or acetone) in the ink
Implementation Method 4
This is followed by a sintering step in order to fuse the particles' boundaries, giving the final part
Data Source
AI summary
Particles each having a sinterable core and a polymeric coating on at least a part of the core, wherein the polymeric coating includes a polymer that can be removed via decomposition by heat, catalytically or by solvent treatment, and wherein the polymeric coating is present in an amount of 0.10 to 3.00% by weight, relative to the total weight of the particles, as well as the use of these particles in an additive manufacturing process such as a powder bed and inkjet head 3D printing process. The particles and the process are able to provide a green part having improved strength and are thus suitable for the production of delicate structures which require a high green strength in order to minimize the risk of structural damage during green part handling.