Thermoplastic Polyurethane Powder Bed 3D Printing Materials
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Solution Overview
Problem
The limitations of 3D printing technology in commercial production due to the restricted range of materials and high costs, which hinder widespread adoption across industries like aviation and medicine, where rapid prototyping and customization are beneficial.
Innovation Solution
Development of materials kits for 3D printing that include thermoplastic polyurethane particles with specific properties, such as average particle sizes and melting temperatures, combined with fusing and detailing agents, to create 3D printed articles with enhanced mechanical properties and controlled fusion processes using electromagnetic energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional 3D printing materials and methods are used, then rapid prototyping capability is achieved, but material range is limited and production costs are high
Solution Approach 1:
The patent applies parameter changes by carefully controlling particle size (20-120 μm) and melting temperature (100-250°C) of thermoplastic polyurethane particles, along with hard segment content (10-30 wt%), to optimize both material versatility and printing cost-effectiveness for commercial production
Solution Approach 2:
The patent uses composite materials by combining thermoplastic polyurethane particles with specific hard segment compositions (including symmetrical aliphatic diisocyanates and chain extenders) to achieve enhanced mechanical properties (tensile strength 20-50 MPa, elongation 1000-4000%) while maintaining cost efficiency
2Manufacturing precision
If electromagnetic energy is used to fuse particles, then fusion control is improved, but energy consumption increases
Solution Approach 1:
The patent exploits phase transitions by using electromagnetic energy to selectively melt thermoplastic polyurethane particles at their specific melting temperature range (100-250°C), enabling precise fusion control while minimizing overall energy consumption through targeted heating only where needed
Solution Approach 2:
The patent replaces mechanical fusion methods with electromagnetic energy-based fusion, allowing non-contact, selective heating and fusion of particles with high precision control, reducing energy waste compared to conventional mechanical heating methods
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 solution enables the production of 3D printed articles with tensile strengths of 20-50 MPa and elongation at break of 1000-4000%, expanding material options and reducing production costs, thus enhancing the capability for commercial production and customization.
Implementation Method 1
a fusing agent including a radiation absorber to selectively apply to the powder bed material
Implementation Method 2
The thermoplastic polyurethane particles can have an average particle size from about 20 μm to about 120 μm and a melting temperature of from about 100° C. to about 250° C.
Implementation Method 3
The hard segments can include a symmetrical aliphatic diisocyanate and a symmetrical aliphatic chain extender that are polymerized into the thermoplastic polyurethane particles
Data Source
AI summary
A materials kit for three-dimensional (3D) printing can include a powder bed material comprising thermoplastic polyurethane particles and a fusing agent including a radiation absorber to selectively apply to the powder bed material. The thermoplastic polyurethane particles can have an average particle size from about 20 μm to about 120 μm and a melting temperature of from about 100° C. to about 250° C., wherein the thermoplastic polyurethane particles include polyurethane polymer strands having an average of about 10 wt % to about 30 wt % hard segments based on a total weight of the thermoplastic polyurethane particles. The hard segments can include a symmetrical aliphatic diisocyanate and a symmetrical aliphatic chain extender that are polymerized into the thermoplastic polyurethane particles.