Two-Part Thermosetting Resin Additive Manufacturing System
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Solution Overview
Problem
Current polymer additive manufacturing is limited by temperature constraints, particularly for flexible materials which degrade at temperatures between 60-80 °C, and high temperature thermoplastics that suffer from residual stresses and warping due to high melt viscosity and temperature gradients.
Innovation Solution
A two-part thermosetting resin additive manufacturing system that mixes and extrudes a resin and hardener on demand through a nozzle, allowing for controlled curing and extended temperature operation range, improved strength, and flexibility, with optional additives for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible materials are used in additive manufacturing, then material flexibility and comfort are improved, but the material degrades at temperatures between 60-80 °C
Solution Approach 1:
The patent changes the fundamental material parameter from thermoplastic to thermosetting resin, which has a completely different thermal behavior profile. Thermosetting resins cure through chemical reaction rather than melting, allowing the part to maintain structural integrity at temperatures where flexible thermoplastics would degrade, thus resolving the contradiction between flexibility and temperature stability
Solution Approach 2:
The patent uses two-part thermosetting resin systems (resin and hardener) that create crosslinked composite structures. This composite approach provides both the flexibility needed for comfortable parts and the thermal stability required to prevent degradation at elevated temperatures
2Temperature
If high temperature thermoplastics are used, then operating temperature range is extended, but residual stresses and warping increase due to high melt viscosity and temperature gradients
Solution Approach 1:
The patent changes the material class from thermoplastic to thermosetting resin, fundamentally altering the processing mechanism. Instead of melting and solidifying, the resin cures through chemical reaction, eliminating the temperature gradients and viscosity issues that cause warping in high-temperature thermoplastics while still allowing high operating temperatures
Solution Approach 2:
The patent performs the curing reaction during the printing process itself, rather than after. This preliminary curing action locks in the dimensional structure before the part is removed from the build plate, preventing warping that would occur if curing happened after cooling and contraction
3Ease of manufacture
If thermoplastic materials are used, then ease of processing is maintained, but the upper use temperature is limited below the extrusion temperature due to material softening
Solution Approach 1:
The patent changes the material from thermoplastic to thermosetting resin, which undergoes irreversible chemical curing rather than reversible melting. This allows the part to withstand temperatures above the printing temperature without softening, as the crosslinked structure maintains rigidity even at elevated temperatures
Solution Approach 2:
The patent performs curing during the printing process, creating a permanently set structure before the part is removed. This preliminary setting action ensures the part maintains its shape and dimensions at temperatures that would cause thermoplastics to soften and deform
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 system achieves improved dimensional accuracy and extended temperature operation range, reducing warping and enhancing the structural integrity of printed parts.
Implementation Method 1
mixing the first material and the second material in a mixer to form a thermosetting resin
Implementation Method 2
a nozzle fluidly connected to the mixer for extruding the thermosetting resin
Data Source
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AI summary
An additive manufacturing system (10) for forming a component (12) on a layer-by-layer basis includes a first pump (26) for pumping a first material and a second pump (28) for pumping a second material. The additive manufacturing system (10) further includes a mixer (16) for receiving and mixing the first material and the second material to form a thermosetting resin, a nozzle (14) fluidly connected to the mixer (16) for extruding the thermosetting resin, and a motion control system (15) connected to the nozzle (14) for moving the nozzle (14) in a predetermined pattern to form a layer of the component (12).