Stabilizing Liquid Functional Material for 3D Printing Coalescence Bleed
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Solution Overview
Problem
In 3D printing, coalescence bleed occurs during multi jet fusion, leading to reduced dimensional accuracy and edge acuity due to thermal energy propagation, causing unintended solidification of surrounding build material.
Innovation Solution
The use of a stabilizing liquid functional material with non-Newtonian fluid properties is deposited to lock build material in place, preventing radiation absorbers from spreading and reducing coalescence bleed by forming a structured network that enhances part definition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal energy is propagated to fuse build material, then curing or sintering is achieved, but coalescence bleed occurs causing reduced dimensional accuracy and edge acuity
Solution Approach 1:
A stabilizing liquid functional material is introduced as an intermediary between the radiation absorber and the build material. This stabilizing material forms a structured network that prevents the radiation absorber from migrating into surrounding build material, thereby eliminating coalescence bleed while maintaining the curing function. The stabilizing material acts as a barrier that mediates the interaction between thermal energy and build material.
Solution Approach 2:
The stabilizing liquid functional material is applied to the build material layer before radiation curing occurs. This preliminary application establishes a structured network that locks the build material in place and prevents subsequent migration of radiation absorbers during the thermal energy propagation process, thereby preventing coalescence bleed before it can occur.
2Use of energy by moving object
If radiation absorbers are used to convert electromagnetic radiation to thermal energy, then curing is achieved, but the absorbers spread to surrounding build material causing coalescence bleed
Solution Approach 1:
The stabilizing liquid functional material serves as an intermediary that binds to the radiation absorber and prevents its migration. The stabilizing material forms a structured network that confines the radiation absorber to the intended area, maintaining stable distribution while preserving the radiation-to-thermal-energy conversion function.
Solution Approach 2:
The stabilizing liquid functional material changes the physical parameters of the system by forming a structured network with specific viscosity and structural properties. This network structure restricts the movement of radiation absorbers while maintaining the optical and thermal properties needed for effective curing.
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 improves the definition and accuracy of 3D objects by preventing unwanted solidification and migration of materials, resulting in enhanced edge acuity and overall part quality.
Implementation Method 1
The stabilizing liquid functional material is capable of absorbing electromagnetic radiation and converting the absorbed radiation to thermal energy
Implementation Method 2
The stabilizing liquid functional material with non-Newtonian fluid properties is deposited to lock build material in place
Data Source
AI summary
A stabilizing liquid functional material (SLFM) for 3D printing includes ceramic nanoparticles in an amount ranging from about 0.25% to about 5% by weight based on a total SLFM weight and silica nanoparticles present in an amount ranging from about 0.1% to about 10% by weight based on the total SLFM weight. The ceramic nanoparticles have a particle size ranging from about 5 nm to about 50 nm. The silica nanoparticles have a particle size ranging from about 10 nm to about 50 nm. The ceramic nanoparticles and the silica nanoparticles are different in composition and/or morphology. An electromagnetic radiation absorber is present in an amount ranging from about 1% to about 10% by weight based on the total SLFM weight. An organic solvent is present in an amount from about 5% to about 50% by weight based on the total SLFM weight. The SLFM includes a balance of water.