3D Printed Object Sintering Contraction Mismatch
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Solution Overview
Problem
Conventional methods for producing three-dimensionally shaped objects with high-density and low-density portions suffer from poor production efficiency and deformation due to differences in contraction rates during sintering.
Innovation Solution
A method involving the lamination of layers using compositions with matched filling rates and average particle diameters of powders, either of the same or different materials, to reduce contraction rate differences and enable collective sintering of high-density and low-density portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-density portion and low-density portion are solidified separately, then deformation is avoided, but production efficiency deteriorates
Solution Approach 1:
The patent combines the solidification process of high-density and low-density portions into a single collective sintering operation. By forming both portions from layers containing powder and organic material, and then sintering them together in one heating process, the production efficiency is improved while deformation is controlled through the matching of filling rates and particle diameters between the two portions.
2Productivity
If high-density portion and low-density portion are collectively sintered using conventional apparatus, then production efficiency is improved, but deformation occurs due to difference in contraction rate
Solution Approach 1:
The patent applies local quality by controlling the composition of each portion differently. The high-density portion uses powder with a first filling rate and first average particle diameter, while the low-density portion uses powder with a second filling rate and second average particle diameter. This local differentiation in material properties allows each portion to have appropriate contraction characteristics during sintering, preventing deformation while enabling collective processing.
Solution Approach 2:
The patent changes key parameters (filling rate and average particle diameter) of the powder materials used in forming the layers. By specifically matching these parameters between the high-density and low-density portions, the contraction rates during sintering are equalized, allowing both portions to be collectively sintered without deformation.
3Manufacturing precision
If filling rate and average particle diameter are matched between layers, then contraction rate difference is reduced, but composition control complexity increases
Solution Approach 1:
The patent systematically controls two key parameters (filling rate and average particle diameter) of the powder materials. By establishing specific relationships between these parameters for different portions (matching filling rates and average particle diameters), the contraction rates are equalized. This parameter-based approach provides a clear, controllable method for achieving uniform contraction without excessive complexity.
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 allows for efficient and deformation-free production of three-dimensionally shaped objects with high-density and low-density portions, enabling applications such as high-performance heat sinks and loop heat pipes by controlling thermal conductivity gradients.
Implementation Method 1
sintering the first powder and the second powder by heating a laminate including the first layer and the second layer
Implementation Method 2
forming a second layer among the layers by using a second composition containing second powder, third powder, and binder, the third powder being an organic material
Data Source
AI summary
A production method of a three-dimensionally shaped object, includes a first layer forming step of forming a first layer by using a first composition containing first powder and binder, a second layer forming step of forming a second layer by using a second composition containing second powder, third powder, and binder, and a sintering step of sintering the first powder and the second powder. In a case where the first powder and the second powder are of the same material, difference in a contraction rate between the first layer and the second layer in the sintering step is reduced by matching a filling rate of the first powder in the first composition with a total filling rate of the second powder and the third powder in the second composition and matching an average particle diameter of the first powder with an average particle diameter of the second powder.