Thermoplastic Elastomer Powders for Low Density 3D Moldings
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Solution Overview
Problem
Current 3D printing technologies using thermoplastic powders face challenges in producing objects with multiple materials or properties, particularly in achieving low density and high rebound resilience, which is essential for expanding prototyping into end-use parts, especially in automotive and footwear industries.
Innovation Solution
Development of thermoplastic elastomer (TPE) powders with specific particle size and sphericity ranges, combined with a process of pulverizing foamed TPE materials and adding auxiliary agents, allows for the creation of 3D moldings with varying properties such as density and rebound resilience through selective bonding techniques like laser sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional thermoplastic powders are used for 3D printing, then the printing process can be performed, but the resulting parts have high density and low rebound resilience
Solution Approach 1:
The patent uses TPE (thermoplastic elastomer) powders as a composite material that combines the benefits of low density with high rebound resilience. The TPE material itself is a composite structure that allows achieving both lightweight properties and mechanical performance, resolving the contradiction between density and rebound resilience in 3D printed parts.
Solution Approach 2:
The patent changes the material parameters by selecting TPE powders with specific properties (particle size D50: 10-1000 μm, sphericity A: 0.05-0.65, sphericity B: 0.05-0.65). By optimizing these parameters, the patent achieves both low density and high rebound resilience, transforming the material characteristics to simultaneously improve both contradictory features.
2Adaptability or versatility
If conventional thermoplastic powders are used, then printing can be performed, but it is difficult to produce parts with multiple materials or multi-performance
Solution Approach 1:
The patent makes the TPE powder material universal by optimizing its properties (particle size, sphericity) to work effectively with various 3D printing technologies (SLS, MJF, SHS). This single material can be used across different printing processes and can produce parts with varying properties by adjusting printing parameters, achieving multi-functionality without requiring multiple specialized materials for each application.
Solution Approach 2:
The patent enables local quality variations within the printed part by using TPE powders that can be selectively processed. Different regions of the printed part can have different densities and properties by controlling the printing parameters (laser power, scan speed, layer thickness) during the manufacturing process, allowing multi-performance parts from a single material type.
3Weight of moving object
If density reduction is attempted through process adjustment, then lower density parts may be achieved, but rebound resilience and mechanical properties deteriorate
Solution Approach 1:
The patent employs TPE as a composite material that inherently provides both low density and high mechanical properties including rebound resilience. The elastomeric nature of TPE creates a composite structure at the material level that maintains strength and elasticity even at reduced densities, preventing the trade-off between weight reduction and mechanical performance.
Solution Approach 2:
The patent changes the fundamental material parameter from conventional thermoplastics to TPE with specific characteristics (sphericity 0.05-0.65, particle size 10-1000 μm). This parameter change enables the material to achieve optimal packing and bonding behavior during printing, resulting in parts with both low density and high mechanical properties including rebound resilience above 50%.
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 approach enables the production of 3D moldings with low density and high rebound resilience, along with good mechanical properties, and the ability to create multiple areas with distinct properties using the same material, enhancing the versatility of 3D printed parts.
Implementation Method 1
selective laser sintering
Implementation Method 2
selective laser sintering (SLS)
Implementation Method 3
pulverizing the foamed TPE material
Data Source
AI summary
This disclosure relates to thermoplastic elastomer (TPE) powders, wherein the average particle size D50 of the TPE powders is in the range from 10 μm to 1 mm and at least one of average sphericity A and average sphericity B of TPE powders is no more than 0.6; to a process of preparing the TPE powders and to a method of preparing the 3D molding. The powders and the method according to the present invention allow to prepare a 3D molding with low density, high rebound resilience and good mechanical properties, especially a 3D molding comprising multiple areas having different properties.