Viscosity-Modified Binder for Stable 3D Printed Casting Molds
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Solution Overview
Problem
Existing 3D printing processes face challenges with binders that have uncontrolled leakage or droplet generation due to inappropriate viscosity, especially when using inkjet print heads, and require binders that provide optimal application and mechanical strength while maintaining thermal stability.
Innovation Solution
A process involving a binder with furfuryl alcohol and a viscosity modifier, such as novolak, is used to achieve a viscosity of 5 to 40 mPas at 25°C, ensuring stable application and enhanced mechanical strength in layer-by-layer production of building structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a binder with low viscosity is used for 3D printing, then the binder can be easily applied through inkjet print head nozzles, but the binder leaks uncontrolledly and forms droplets instead of individual deposits
Solution Approach 1:
The patent modifies the viscosity parameter of the binder by adding a viscosity modifier (such as carboxymethyl cellulose or hydroxyethyl cellulose) to achieve an optimal viscosity range of 5-40 mPa·s at 25°C. This parameter adjustment allows the binder to flow through inkjet nozzles while maintaining sufficient cohesion to prevent uncontrolled leakage and droplet formation, thus resolving the contradiction between ease of application and precision control.
2Manufacturing precision
If a binder with high viscosity is used to prevent leakage, then droplet formation is controlled, but the binder cannot be properly applied through inkjet print head nozzles
Solution Approach 1:
The patent optimizes the viscosity parameter to a specific range (5-40 mPa·s at 25°C) that balances both requirements. The viscosity modifier enables the binder to have sufficiently high viscosity to control droplet formation while remaining low enough to flow through inkjet nozzles, thus resolving the contradiction between precision control and ease of application.
3Device complexity
If conventional binders are used without viscosity modifiers, then the formulation is simple, but the binder exhibits uncontrolled leakage and poor storage stability
Solution Approach 1:
The patent introduces a viscosity modifier as an intermediary substance that mediates between the binder components to achieve stable rheological properties. This intermediary agent (such as carboxymethyl cellulose or hydroxyethyl cellulose) prevents uncontrolled leakage and improves storage stability without significantly complicating the binder formulation, thus resolving the contradiction between formulation simplicity and reliability.
4Device complexity
If the binder viscosity is not optimized, then the binder formulation is simple, but the mechanical strength of the produced building structures is insufficient
Solution Approach 1:
The patent optimizes the viscosity parameter of the binder to ensure proper application through inkjet printing while maintaining sufficient mechanical strength. The viscosity modifier enables the binder to form strong bonds between layers and within layers, resulting in building structures with adequate mechanical strength without significantly increasing formulation complexity.
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 binder system with a viscosity modifier provides improved strength and stability, allowing for effective 3D printing with reduced leakage and droplet issues, resulting in higher mechanical strength and storage stability compared to binders without the modifier.
Implementation Method 1
the binder has a viscosity of 5 to 40 mPas at 25° C.
Implementation Method 2
The binder creates a firm bond between the particles/grains of the molding base material so that the molded body has the required mechanical stability.
Implementation Method 3
The material of the molded body must now decompose under the influence of the heat emitted by the metal in such a way that it loses its mechanical strength, i.e. the cohesion between individual particles/grains of the refractory material is broken down.
Data Source
AI summary
The subject of the invention is a process for the layer-by-layer production of a building structure using furfuryl alcohol and novolaks as a viscosity modifier, building structures produced in this way, such as cores or molds for metal casting and their use, as well as a binder and a kit comprising binder and, separately therefrom, hardener.