Twisted 3D Printing Strand for Impact Strength
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Solution Overview
Problem
Existing 3D printing techniques using fused deposition modeling struggle to produce objects with excellent impact strength due to buckling issues when using continuous fibers impregnated in thermoplastic resin, making them difficult to handle and form effectively.
Innovation Solution
A strand is developed with thermoplastic resin as the main component, impregnated with one or more fibers or fiber bundles that are twisted along the axial direction, reducing buckling and enhancing handleability and impact strength, with a preferred twisting rate of 10-200 times per meter and angle of 3-50 degrees, utilizing carbon fibers for improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fibers are impregnated in thermoplastic resin to form a strand for 3D printing, then the impact strength of the molded object is improved, but the strand becomes rigid and easily buckled, making it difficult to handle
Solution Approach 1:
The patent applies parameter changes by modifying the physical state of the thermoplastic resin from solid to molten state during impregnation. This allows the resin to flow and coat the fibers uniformly, creating a strand that maintains flexibility when cold (easy to handle) but provides strength when processed (excellent impact strength in molded object).
Solution Approach 2:
The patent uses composite materials by combining continuous inorganic fibers (such as carbon fibers) with thermoplastic resin to form a stranded structure. This composite approach allows the fiber to provide impact strength while the resin matrix provides flexibility and handleability, resolving the contradiction between strength and ease of operation.
2Strength
If multiple fibers or fiber bundles are impregnated in thermoplastic resin, then the mechanical strength is improved, but the strand becomes more complex and difficult to wind up
Solution Approach 1:
The patent merges multiple fibers or fiber bundles into a single stranded structure by impregnating them together with thermoplastic resin. This combining approach consolidates multiple elements into one unified strand that maintains the mechanical strength benefits of multiple fibers while simplifying handling and winding operations compared to managing separate fibers.
Solution Approach 2:
The patent uses parameter changes by controlling the viscosity and flow characteristics of the molten thermoplastic resin during impregnation. This allows multiple fibers to be uniformly coated and bound together into a flexible strand that is easy to wind and handle, reducing structural complexity despite containing multiple fiber elements.
3Ease of operation
If fibers are impregnated in thermoplastic resin in a molten state, then the strand exhibits good handleability, but the impregnated object is rigid and easily buckled
Solution Approach 1:
The patent applies parameter changes by utilizing the temperature-dependent properties of thermoplastic resin. When molten, the resin provides fluidity and flexibility for easy impregnation and handling. When cooled, the resin solidifies to provide structural stability and prevent buckling, thus resolving the contradiction between handleability and structural stability.
Solution Approach 2:
The patent employs phase transitions of the thermoplastic resin between molten and solid states. During impregnation, the resin is in a molten phase that allows easy coating and handling. After impregnation, the resin transitions to a solid phase that provides structural stability and prevents buckling, effectively resolving the contradiction between handleability and structural stability.
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 twisted strand allows for the easy formation of 3D printed objects with enhanced impact strength by distributing the thermoplastic resin component and reducing fiber rupturing, resulting in improved mechanical properties and handleability.
Implementation Method 1
a continuous fiber made of an inorganic material such as a carbon fiber is, as a raw modeling material suitable for the 3D printer, impregnated in thermoplastic resin in a molten state
Data Source
AI summary
Provided is a strand from which a modeled object with excellent impact strength can be easily formed by a 3D printer and a modeled object with excellent impact strength.A strand of the present disclosure is a strand used as a raw modeling material for a 3D printer, the strand including a base material containing thermoplastic resin as a main component and one or more fibers or fiber bundles impregnated in the base material and extending in an axial direction and the strand being twisted along the axial direction.