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WO2025170467A1 - Procédé et système d'impression 3d, ainsi qu'une bobine pourvue d'un filament d'un matériau polymère destiné à être utilisé dans le procédé - Google Patents

Procédé et système d'impression 3d, ainsi qu'une bobine pourvue d'un filament d'un matériau polymère destiné à être utilisé dans le procédé

Info

Publication number
WO2025170467A1
WO2025170467A1 PCT/NL2025/050056 NL2025050056W WO2025170467A1 WO 2025170467 A1 WO2025170467 A1 WO 2025170467A1 NL 2025050056 W NL2025050056 W NL 2025050056W WO 2025170467 A1 WO2025170467 A1 WO 2025170467A1
Authority
WO
WIPO (PCT)
Prior art keywords
filament
polymeric material
spool
printhead
room temperature
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/NL2025/050056
Other languages
English (en)
Inventor
Patrick Gerardus DUIS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tectonic 3d Swip BV
Original Assignee
Tectonic 3d Swip BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tectonic 3d Swip BV filed Critical Tectonic 3d Swip BV
Publication of WO2025170467A1 publication Critical patent/WO2025170467A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing

Definitions

  • the invention in general pertains to the art of 3D printing, also known as additive manufacturing, and in particular to the technology called fused deposition modeling (FDM).
  • FDM is a form of 3D printing technology that falls under the general process of material extrusion.
  • a typical system for FDM comprises 1) a printhead comprising a nozzle for expelling fusible polymeric material through the nozzle onto a support while forming a 3D object, 2) a spool having wound thereon a continuous length of a filament of the said polymeric material and 3) an extruder positioned downstream of the spool and upstream of the printhead, for controlling a supply of the filament towards the printhead.
  • the printhead thus being able to expel a continuous stream of fusible polymeric material on the support.
  • the invention in particular pertains to an FDM process wherein a polymeric material is used having a very high modulus.
  • 3D printing can create physical objects from a geometrical representation by successive addition of material.
  • the 3D printing process was first commercialised in the year 1980 by Charles Hull but has experienced a phenomenal expansion in recent years.
  • 3D printing is for example used for producing artificial heart pumps, jewellery, producing cornea, parts for rocket engines, airplanes, buildings and other products related for example to the aviation industry as well as the food industry.
  • 3D printing technology has originated from the layer-by-layer fabrication technology of three- dimensional structures directly from computer-aided design (CAD) drawings.
  • CAD computer-aided design
  • 3D printing technology has the potential to revolutionise industries and change production methods. The adoption of 3D printing technology will increase the production speed while reducing costs. At the same time, the demand of the consumer will have more influence over production. Consumers have greater input in the final product and can request to have it produced to fit their specifications. At the meantime, the facilities of 3D printing technology will be located closer to the consumer, allowing for a more flexible and responsive manufacturing process, as well as greater quality control. Furthermore, when using 3D printing technology, the need for global transportation is significantly decreased.
  • Typical polymers used for the polymeric materials for use in 3D printing technology are polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyethylene terephthalate glycol (PETG), acrylonitrile styrene acrylate (ASA), Polyamide 6, PA6.66, PA66.6, PA11 and PA12 polypropylene (PP) or polyethylene (PE).
  • PLA polylactic acid
  • ABS acrylonitrile butadiene styrene
  • PETG polyethylene terephthalate glycol
  • ASA acrylonitrile styrene acrylate
  • thermoplastics filaments with higher melting temperatures and higher moduli such as polyether ether ketone (PEEK) (or other members of the peak family such as PEAK, PEKK, PEK and semi crystalline forms thereof), polyphtalamide (PPA), polyketone (PK), poly(p-phenylene oxide) (PPO OR PPE), poly ether imide (PEI), polyimide (PI), polyphenylene sulfide (PPS), polyethersulfone (PESU), polysulfone (PES) and polymethyl methacrylate (PMMA) are used as materials for 3D printing technology.
  • PEEK polyether ether ketone
  • PPA polyketone
  • PPO OR PPE poly(p-phenylene oxide)
  • PEI poly ether imide
  • PI polyimide
  • PPS polyphenylene sulfide
  • PESU polyethersulfone
  • PMMA polymethyl methacrylate
  • continuous filaments of the polymeric material are used for supply of the material to the printhead, wherein the filaments have a length of at least 100 meters (typically 200-500 m), and a diameter of about 1.5 to 2 mm.
  • the continuous length is needed in order to make sure the printing process is not interrupted.
  • a higher thickness would be advantageous since more material can be supplied per length of filament, this is often not possible since the filament is wound on a spool. Too thick filaments cannot be wound without the risk of breaking.
  • the polymeric material may have a Young’s modulus that is too high for allowing winding of this filament on a spool. This means that at this moment, ultra strong polymer materials, e.g.
  • fibre-filled PEEK cannot be used in a high quality industrial FDM processes that relies on a continuous supply of a filament from a spool.
  • a solution that is used is to use an unfilled high modulus polymeric material, and co-extrude a continuous fibre into the filament just before the printhead. This may indeed serve to reach certain mechanical properties that are higher than based on the polymeric material alone, but the effect is minimal at the cost of a more complicated printing process, needing co-extrusion and the cutting of the fibres after each stretch of deposited material. It is thus commonly accepted that for obtaining 3D printed objects that need to have a very high strength, other materials that polymeric material must be used, typically metals.
  • the system further comprises a unit (such as a robot arm) to automatically fuse a (for example precut) length of the filament (which may be cut form a filament wound on another spool, or cut before or after object is printed from a filament that is on the same spool, or in any other way) to a surface of the 3D object.
  • a unit such as a robot arm
  • a unit to automatically fuse a (for example precut) length of the filament (which may be cut form a filament wound on another spool, or cut before or after object is printed from a filament that is on the same spool, or in any other way) to a surface of the 3D object.
  • FIG. 2 is a schematic representation of an FDM system according to the invention.
  • Figure 5 shows an object printed with a system according to the invention.
  • Example 1 is an example of printing an 3D object using the system and method according to the invention.
  • FIG 1 is a schematic representation of an FDM system 1 as known in the art, for printing high quality objects.
  • a spool 2 on which a filament 3 of a polymeric material is wound is first fed towards the FDM printhead, comprising heater block 5 and nozzle 6.
  • the nozzle typically has a small diameter of about 0.6 mm. However, larger nozzles may be useful in case a higher output speed is necessary.
  • the filament 3 is fed into an extruder 4, which uses a gear and a bearing to control the flow of filament into the heated block 5 and nozzle 6. Once the heating block reaches the correct temperature, the filament is fed into the nozzle and is further heated by this nozzle (corresponding to the process in a glue gun, but with filament instead of hot glue).
  • the material 7 in fusible form is extruded (or “drawn”) onto the build platform 9 (acting as a support) in the x-y plane, where it quickly cools into the desired cross-sectional shape 8.
  • the printhead crosses the platform in x-y plane and adjusts vertically (on the z-axis) so that another layer can be placed on top of the previous layer, and the process repeats until the printer has completed the object (not shown as a complete part in figure 1).
  • This entire assembly is directed and controlled via a controller board, or a microprocessor that handles the x-y-z movement, temperature regulation, and software integration for the FDM printer as is commonly known in the art
  • FIG 2 is a schematic representation of an FDM system T according to the invention.
  • the system differs from the one shown in figure 1 in that the filament 3a has the form of a tape (see figure 3 for details), and in that the extruder is composed of two separate parts 4a and 4b.
  • the filament 3a is heated and re-shaped to become more circular (attaining a higher roundness). It leaves the first part 4a and is fed as a reshaped filament 3b to the second part of the extruder 4b, where the filament is further heated and re-shaped to attain a roundness of 0.95, to become further re-shaped filament 3c.
  • the basic FDM process thereafter for producing the object 8 is the same as indicated in figure 1.
  • the novel system in this embodiment also comprises a robot 10, which has an arm 11 for the precise placement of parts onto the object 8 after the basic FDM process.
  • a part may be a pre-cut length of the filament 3a.
  • the robot 10 also comprises a laser arm 12 for locally heating the polymeric material, such that the filament can be fused to the object. This is shown in more detail in figure 5.
  • Figure 3 shows basic parts for an alternative FDM system.
  • the extruder 4 and heated block 5 with nozzle 6 are shown, through which elements tape shaped filament 3 is transported, and ultimately melted in block 5 to be expelled in liquid (paste) form from nozzle 6 (having a diameter of 0.4 mm in this case).
  • the filament may be pre-heated but is not yet re-shaped, it keeps its tape form.
  • heated block 5 there is a reducer part 55, which at its entrance 56 is formed to accommodate the tape shape (see figure 3B for more detail), and at its outlet 57, i.e. at the entrance of the nozzle 6, is formed to produce a circular filament with a roundness of around 0.95 or more.
  • This reducer piece can be used in a more or less standard heated block to be able and apply the current invention.
  • Figure 3B shows the reducer in more detail.
  • Figure 5 shows an object 8, printed using the system of figure 2, and being provided with three strips of the filament 3a, fused to the surface of the 3D object 8.
  • Each of the lengths which may be pre-cut or cut by the unit right after printing, is fused to the object 8 such that it extends in the Z-direction, i.e. the direction in which the polymeric material is layered in the object. This way the strength of the object in this direction is substantially improved.
  • Example 1 is an example of printing an 3D object using the system and method according to the invention, wherein a 3D object is printed using a 30% carbon fibre filled PEEK (available e.g. from Victrex Pic, Lancashire), having a Young’s modulus of 28 GPa and a Tensile strength of 265 MPa.
  • the filament can be provided wound on a standard spool with a diameter of 20 cm, and a core of 5 cm, without a substantial risk of breaking this highly rigid material.
  • the length of the filament is about 320 metres, enough to print relatively large objects without any discontinuity in the supply. Comparable results are obtainable with a 30% carbon fibre filled PP, a 20% carbon fibre filled PA11 and a 15% carbon fibre filled rPEEK.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

L'invention concerne un système (1) pour réaliser un procédé de modélisation par dépôt de fil fondu, le système comprenant : 1) une tête d'impression comprenant une buse (6) pour expulser un matériau polymère fusible (7) à travers la buse sur un support (9) tout en formant un objet 3D (8), le matériau polymère présentant un module de Young supérieur à 12 GPa à température ambiante, 2) une bobine (2) sur laquelle est enroulée une longueur continue d'un filament dudit matériau polymère, et 3) une extrudeuse (4) positionnée en aval de la bobine et en amont de la tête d'impression, pour commander une alimentation du filament vers la tête d'impression, le filament étant façonné sous la forme d'une bande. L'invention concerne également un procédé faisant appel à ce système et une bobine sur laquelle est enroulé un filament d'un matériau polymère destiné à être utilisé dans le système et le procédé.
PCT/NL2025/050056 2024-02-06 2025-02-04 Procédé et système d'impression 3d, ainsi qu'une bobine pourvue d'un filament d'un matériau polymère destiné à être utilisé dans le procédé Pending WO2025170467A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL2036973A NL2036973B1 (en) 2024-02-06 2024-02-06 A method and system for 3d printing, as well as a spool provided with a filament of a polymeric material for use in the method
NL2036973 2024-02-06

Publications (1)

Publication Number Publication Date
WO2025170467A1 true WO2025170467A1 (fr) 2025-08-14

Family

ID=94605635

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/NL2025/050056 Pending WO2025170467A1 (fr) 2024-02-06 2025-02-04 Procédé et système d'impression 3d, ainsi qu'une bobine pourvue d'un filament d'un matériau polymère destiné à être utilisé dans le procédé

Country Status (2)

Country Link
NL (1) NL2036973B1 (fr)
WO (1) WO2025170467A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3313647B1 (fr) * 2015-06-29 2020-05-06 Covestro Deutschland AG Procédé de fabrication d'objets 3d
EP3888879A1 (fr) * 2020-04-02 2021-10-06 Universitat de Girona Tête d'extrusion et procédé de fabrication de filaments fusionnés en continu

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3313647B1 (fr) * 2015-06-29 2020-05-06 Covestro Deutschland AG Procédé de fabrication d'objets 3d
EP3888879A1 (fr) * 2020-04-02 2021-10-06 Universitat de Girona Tête d'extrusion et procédé de fabrication de filaments fusionnés en continu

Also Published As

Publication number Publication date
NL2036973B1 (en) 2025-08-20

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