Thermoplastic Resin Composition for 3D Printing
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Solution Overview
Problem
Existing methods for producing three-dimensional objects using resin particles, such as powder bed fusion and Multi Jet Fusion, face challenges in achieving high strength and ductility simultaneously, as additives like thermosetting rubber particles or ionomer resins either inhibit fusion or result in objects with insufficient mechanical strength.
Innovation Solution
A three-dimensional object-forming resin composition comprising a thermoplastic resin with a disperse phase of thermoplastic elastomer, where the thermoplastic elastomer is dispersed in a continuous phase of thermoplastic resin, and optionally including fillers, to achieve a balance of high strength and ductility by controlling the amount of thermoplastic elastomer and filler content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If thermosetting rubber particles are added to resin particles for powder bed fusion or MJF method, then the ductility of the resultant three-dimensional object is improved, but the strength and object-forming accuracy decrease due to inhibition of fusion
Solution Approach 1:
The patent changes the physical state and compatibility parameters of the rubber component by using thermoplastic elastomer instead of thermosetting rubber, and by controlling the rubber content within 1-12 parts by mass per 100 parts of thermoplastic resin. This parameter optimization allows the rubber to improve ductility without excessively interfering with fusion, resolving the contradiction between ductility improvement and strength maintenance.
Solution Approach 2:
The patent creates a composite resin particle system combining thermoplastic resin and thermoplastic elastomer in specific proportions. This composite approach allows the material to exhibit both the structural integrity needed for strength and the flexibility needed for ductility, while the controlled composition ensures proper fusion characteristics for 3D printing processes.
2Stability of the object's composition
If ionomer resin and polyamide elastomer are combined to improve break elongation, then ductility is improved, but sufficient increase in ductility cannot be achieved while maintaining strength
Solution Approach 1:
The patent optimizes the parameter combination by selecting thermoplastic elastomer with specific compatibility characteristics and controlling it within a narrow range of 1-12 parts by mass per 100 parts of thermoplastic resin. This precise parameter control achieves sufficient ductility improvement while maintaining strength, overcoming the limitations of broader combinations like ionomer resin and polyamide elastomer.
3Stability of the object's composition
If thermoplastic resin and rubber-reinforced styrene-based resin are melt-kneaded together, then ductility is improved through high compatibility, but strength becomes insufficient
Solution Approach 1:
The patent modifies the compatibility parameter by using thermoplastic elastomer with controlled compatibility rather than highly compatible rubber-reinforced styrene-based resin. The specific constraint of 1-12 parts by mass per 100 parts of thermoplastic resin creates an optimal balance where sufficient compatibility provides ductility while avoiding excessive mixing that would compromise strength.
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 resin composition enables the production of three-dimensional objects with high dimensional accuracy, strength, and ductility by effectively distributing stress and preventing crack formation, while maintaining sufficient mechanical strength.
Implementation Method 1
The resin composition enables the production of three-dimensional objects with high dimensional accuracy, strength, and ductility by effectively distributing stress and preventing crack formation
Implementation Method 2
the thin layer is irradiated with a laser beam in a pattern... resin particles in the region irradiated with the laser beam are selectively fused
Implementation Method 3
forming a thin layer composed of resin particles including a thermoplastic resin, and sintering or fusing together resin particles in a desired region
Data Source
AI summary
The present invention addresses the problem of providing a three-dimensional modeled article having high dimensional precision, high strength, and high ductility, and a resin composition for a three-dimensional modeled article, the resin composition being used to fabricate the three-dimensional modeled article, and of providing a method for manufacturing a three-dimensional modeled article. To address this problem, a resin composition for a three-dimensional modeled article according to the present invention contains resin particles having a continuous phase including a thermoplastic resin, and a dispersed phase including a thermoplastic elastomer, dispersed in the continuous phase, the amount of the thermoplastic elastomer therein being 1-12 parts by mass with respect to a total of 100 parts by mass of the thermoplastic resin and the thermoplastic elastomer.