Thermoplastic Polyurethane Powder Mixture for Additive Manufacturing
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in fine-tuning mechanical and chemical properties of multi-material 3D printed objects, particularly with polyamides, due to wide melting point ranges, limiting the cohesive connection and cost-effectiveness of structural layers.
Innovation Solution
A method using a mixture of powdered thermoplastic polyurethane materials with varying Shore hardness, combined with other additives, to achieve precise control over mechanical and chemical properties through transurethanization reactions, allowing for a wide range of mechanical and chemical properties within a small processing temperature window.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple polyamide materials with different melting points are mixed to fine-tune mechanical properties, then material property variation is achieved, but processing temperature control becomes difficult and cohesive connection deteriorates
Solution Approach 1:
The patent changes the material parameter from polyamide to thermoplastic polyurethane, which has a narrow melting point range (150-220°C) compared to polyamides (178-260°C). This allows precise processing temperature control (180-260°C) while still achieving mechanical property variation through Shore hardness differences in the TPU materials.
Solution Approach 2:
The patent uses composite material strategy by mixing multiple powdered TPU materials with different Shore hardness values (e.g., 80A, 90A, 95A, 98A) in specific weight ratios. This creates a multi-material system where each component contributes different mechanical properties, enabling fine-tuning of the final object's characteristics while maintaining compatible processing temperatures.
2Reliability
If processing temperature is increased to melt all materials, then complete melting is achieved, but energy consumption increases and material degradation occurs
Solution Approach 1:
The patent selects TPU materials with melting points within 150-220°C, which are lower than polyamides. This allows processing at 180-260°C, achieving complete melting of all TPU components while reducing energy consumption compared to processing polyamides at higher temperatures (178-260°C), and preventing thermal degradation.
3Loss of energy
If processing temperature is decreased to save energy, then energy consumption is reduced, but melting completeness decreases and layer bonding deteriorates
Solution Approach 1:
The patent optimizes the processing temperature range to 180-260°C, which is sufficient to melt TPU materials with melting points of 150-220°C completely. This ensures proper layer bonding and cohesive connection while maintaining energy efficiency, as the temperature is not excessively high like in polyamide processing.
4Adaptability or versatility
If multiple thermoplastic materials are used to achieve property variation, then mechanical properties can be tuned, but material compatibility and cohesive connection become problematic
Solution Approach 1:
The patent uses composite material strategy by mixing multiple powdered TPU materials with different Shore hardness values (e.g., 80A, 90A, 95A, 98A) in specific weight ratios. This creates a multi-material system where each component contributes different mechanical properties, enabling fine-tuning of the final object's characteristics while maintaining compatible processing temperatures.
Solution Approach 2:
The patent maintains material compatibility by using only thermoplastic polyurethane materials, which are chemically compatible and can be processed together. The TPU materials form a homogeneous mixture at the particle level during processing, ensuring cohesive connection and stable composition throughout the object, unlike incompatible material combinations.
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
Enables the production of objects with improved strength, abrasion resistance, and controlled elongation at break, while allowing for spatial variation in properties, resulting in enhanced cohesive layer bonding and cost-effective, resource-efficient manufacturing.
Implementation Method 1
achieving the highest possible cohesive connection of the individual structural layers within the object
Data Source
AI summary
The present invention relates to a method for producing an object, comprising the step of producing the object according to an additive production process from a construction material, wherein the construction material comprises a mixture of a plurality of powdery thermoplastic materials which are different from one another due to at least one mechanical property and at least one thermoplastic material is a thermoplastic polyurethane material. The invention also relates to an object obtained according to said method.