| WO2015109141A1 | 2015-07-23 |
| EP3540012A1 | 2019-09-18 |
RICHTER ALEC: "How To Succeed When Printing With Flexible Filament | MatterHackers", MATTERHACKERS, 9 September 2020 (2020-09-09), pages 1 - 23, XP055818134, Retrieved from the Internet
| Claims 1. An additive manufacturing method comprising the fabrication of an article in a fused deposition modeling process from a build material comprising a thermoplastic polyurethane; wherein the build material has a crystallization temperature of≥ 80 °C as determined by differential scanning calorimetry according to DIN EN ISO 11357 at a cooling rate of 10 K/min, a storage modulus G’20 at 20 °C as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min, a storage modulus G’100 at 100 °C as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min and a ratio G’100/G’20 of ≥ 0.2; wherein the build material is molten inside a printing head comprising a nozzle with a length Koz and an internal diameter dNozof ≥ 1,7 mm to ≤ 1,8 mm or of ≥ 2,8 mm to ≤ 2,9 mm; such that the molten build material has a maximum temperature Tmax and such that the molten build material has a maximum internal pressure pmax and wherein the molten build material is expelled through an unclogged die of the nozzle at a mass rate rh, the die having a length tie an internal diameter duie of ≥ 0,9 mm to ≤ 1,1 mm or of ≥ 0,3 mm to ≤ 0,5 mm, characterized in that a) for the nozzle having an internal diameter dNoz of ≥ 1,7 mm to ≤ 1,8 mm and the die having an internal diameter duie of ≥ 0,9 mm to ≤ 1,1 mm: aa) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: Tmax is ≥ 220 °C to ≤ 230 °C and pmax is ≥ 300 kPa to ≤ 600 kPa; ab) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: Tmax is ≥ 235 °C to ≤ 245 °C and Pmax is ≥ 400 kPa to ≤ 850 kPa; b) for the nozzle having an internal diameter dNoz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter dDie of ≥ 0,9 mm to ≤ 1,1 mm: ba) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: Tmax is ≥ 220 °C to ≤ 230 °C and pmax is ≥ 200 kPa to ≤ 450 kPa; bb) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: Tmax is ≥ 235 °C to ≤ 245 °C and Pmax is ≥ 280 kPa to ≤ 550 kPa; c) for the nozzle having an internal diameter dNoz of ≥ 1,7 mm to ≤ 1,8 mm and the die having an internal diameter dDie of ≥ 0,3 mm to ≤ 0,5 mm: ca) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and pmax is ≥ 900 kPa to ≤ 1900 kPa; cb) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 2500 kPa to ≤ 4500 kPa; and d) for the nozzle having an internal diameter dNoz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter dDie of ≥ 0,3 mm to ≤ 0,5 mm: da) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and pmax is ≥ 900 kPa to ≤ 1900 kPa; db) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 2500 kPa to ≤ 4500 kPa. 2. The method according to claim 1, wherein: a) for the nozzle having an internal diameter dNoz of ≥ 1.7 mm to ≤ 1.8 mm and the die having an internal diameter dDie of ≥ 0,9 mm to ≤ 1,1 mm: aaa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: Tmax is ≥ 220 °C to ≤ 230 °C and Pmax is ≥ 300 kPa to ≤ 330 kPa; aab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: Tmax is ≥ 220 °C to ≤ 230 °C and Pmax is ≥ 565 kPa to ≤ 595 kPa; aba) for the mass rate rh being ≥ 75 mg/s to ≤ 85 mg/s: Tmax is ≥ 235 °C to ≤ 245 °C and Pmax is ≥ 415 kPa to ≤ 445 kPa; abb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: Tmax is ≥ 235 °C to ≤ 245 °C and Pmax is ≥ 765 kPa to ≤ 795 kPa; b) for the nozzle having an internal diameter dNoz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter dDie of ≥ 0,9 mm to ≤ 1,1 mm: baa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: Tmax is ≥ 220 °C to ≤ 230 °C and Pmax is ≥ 200 kPa to ≤ 230 kPa; bab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: Tmax is ≥ 220 °C to ≤ 230 °C and Pmax is ≥ 380 kPa to ≤ 410 kPa; bba) for the mass rate rh being ≥ 75 mg/s to ≤ 85 mg/s: Tmax is ≥ 235 °C to ≤ 245 °C and Pmax is ≥ 280 kPa to ≤ 310 kPa; bbb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: Tmax is ≥ 235 °C to ≤ 245 °C and Pmax is ≥ 510 kPa to ≤ 540 kPa; c) for the nozzle having an internal diameter dNoz of ≥ 1.7 mm to ≤ 1.8 mm and the die having an internal diameter dDie of ≥ 0,3 mm to ≤ 0,5 mm: caa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 1010 kPa to ≤ 1040 kPa; cab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 1735 kPa to ≤ 1765 kPa; cba) for the mass rate rh being ≥ 75 mg/s to ≤ 85 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 2825 kPa to ≤ 2855 kPa; cbb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 4330 kPa to ≤ 4360 kPa; and d) for the nozzle having an internal diameter dNoz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter dDie of ≥ 0,3 mm to ≤ 0,5 mm: daa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 1010 kPa to ≤ 1040 kPa; dab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 1735 kPa to ≤ 1765 kPa; dba) for the mass rate rh being ≥ 75 mg/s to ≤ 85 mg/s: Tmax is ≥ 250 °C to ≤ 250 °C and Pmax is ≥ 2765 kPa to ≤ 2795 kPa; dbb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: Tmax is ≥ 250 °C to ≤ 260 °C and Pmax is ≥ 4215 kPa to ≤ 4245 kPa. 3. The method according to claim 1 or 2, wherein the ratio 1Noz: dNoz is ≥ 4:1 to ≤ 7: 1. 4. The method according to any one of the preceding claims, wherein the build material has a crystallization temperature of ≥ 80 °C to ≤ 85 °C as determined by differential scanning calorimetry according to DIN EN ISO 11357 at a cooling rate of 10 K/min. 5. The method according to any one of the preceding claims, wherein the build material has a storage modulus G’20 at 20 °C of ≥ 50 MPa to ≤ 60 MPa as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min. 6. The method according to any one of the preceding claims, wherein the build material has a storage modulus G’100 at 100 °C of ≥ 15 MPa to ≤ 25 MPa as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min. 7. The method according to any one of the preceding claims, wherein the build material has a ratio G’100/G’20 of≥ 1:4 to ≤ 1: 1.5. 8. The method according to any one of the preceding claims, wherein the build material has a Shore A hardness according to DIN ISO 7619-1 of ≥ 82 to ≤ 87. 9. The method according to any one of the preceding claims, wherein the polyurethane is obtainable by the reaction of: a) a polyisocyanate component comprising an aromatic diisocyanate, an aliphatic diisocyanate or a mixture of the aforementioned substances; b) a polyol component comprising poly (tetramethylene ether glycol), polybutylene adipate or a mixture of the aforementioned substances and c) a chain extender component comprising a linear a,co-alkylene diol. 10. The method according to any one of the preceding claims, wherein the article is a fluid- controlled actuator. |
The present invention relates to fused deposition modeling method operating parameters in conjunction with a certain class of thermoplastic polyurethanes.
The use of thermoplastic polyurethanes (TPU) as build materials in additive manufacturing (3D printing) processes is known.
WO 2015/109141 Al discloses systems and methods for solid freeform fabrication as well as various articles made using the same, where the systems and methods utilize certain thermoplastic polyurethanes which are particularly suited for such processing. The useful thermoplastic polyurethanes are derived from (a) a polyisocyanate component, (b) a polyol component, and (c) an optional chain extender component where the resulting thermoplastic polyurethane has a crystallization temperature above 80 °C and retains more than 20% of its shear storage modulus at 100°C relative to its shear storage modulus at 20°C.
The viscosity of a molten TPU depends upon, inter alia, its shear rate, pressure and temperature. Viscosity characteristics of the molten TPU can influence the result of the 3D printing process, for example the total time needed to print the desired article, the resolution achievable and the deviations from dimensional stability as a result of warping in the finished article. Furthermore, melt dripping of polymer out of the printing head is undesirable since countermeasures such as retracting the filament have to be taken.
The present invention has the object of providing optimized 3D printing parameters in a fused deposition modeling (FDM) process for a certain type of TPU build material. This object is achieved by a method according to claim 1. Advantageous embodiments are the subject of the dependent claims. They may be combined freely unless the context clearly indicates otherwise.
Accordingly, an additive manufacturing method is provided which comprises the fabrication of an article in a fused deposition modeling process from a build material comprising a thermoplastic polyurethane; wherein the build material has a crystallization temperature of ≥ 80 °C as determined by differential scanning calorimetry according to DIN EN ISO 11357 at a cooling rate of 10 K/min, a storage modulus G’ 20 at 20 °C as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min, a storage modulus G’ 100 at 100 °C as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min and a ratio G’ 100 / G’ 20 of ≥ 0.2; wherein the build material is molten inside a printing head comprising a nozzle with a length 1 Noz and an internal diameter d Noz a) of ≥ 1.7 mm to ≤ 1.8 mm or b) of ≥ 2.8 mm to ≤ 2.9 mm; such that the molten build material has a maximum temperature T max and such that the molten build material has a maximum internal pressure p max and wherein the molten build material is expelled through an unclogged die of the nozzle at a mass rate rh, the die having a length tie an internal diameter d Die of ≥ 0,9 mm to ≤ 1,1 mm or of ≥ 0,3 mm to ≤ 0,5 mm.
The method furthermore provides for that: a) for the nozzle having an internal diameter d Noz of ≥ 1,7 mm to ≤ 1,8 mm and the die having an internal diameter d Die of ≥ 0,9 mm to ≤ 1,1 mm: aa) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: T max is ≥ 220 °C to ≤ 230 °C and pma X is ≥ 300 kPa to ≤ 600 kPa; ab) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: T max is ≥ 235 °C to ≤ 245 °C and p max is ≥ 400 kPa to ≤ 850 kPa; b) for the nozzle having an internal diameter d Noz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter d Die of ≥ 0,9 mm to ≤ 1,1 mm: ba) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: T max is ≥ 220 °C to ≤ 230 °C and p max is ≥ 200 kPa to ≤ 450 kPa; bb) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: T max is ≥ 235 °C to ≤ 245 °C and p max is ≥ 280 kPa to ≤ 550 kPa; c) for the nozzle having an internal diameter d Noz of ≥ 1,7 mm to ≤ 1,8 mm and the die having an internal diameter d Die of ≥ 0,3 mm to ≤ 0,5 mm: ca) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: T max is ≥ 250 °C to ≤ 260 °C and p max is ≥ 900 kPa to ≤ 1900 kPa; cb) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: T max is ≥ 250 °C to ≤ 260 °C and p max is ≥ 2500 kPa to ≤ 4500 kPa; and d) for the nozzle having an internal diameter d Noz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter d Die of ≥ 0,3 mm to ≤ 0,5 mm: da) for the mass rate rh being ≥ 15 mg/s to ≤ 60 mg/s: T max is ≥ 250 °C to ≤ 260 °C and p max is ≥ 900 kPa to ≤ 1900 kPa; db) for the mass rate rh being > 60 mg/s to ≤ 165 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 2500 kPa to ≤ 4500 kPa.
It has been found that in an FDM process using the material, parameters and machine settings according to the invention the total melt dripping from the printing head, expressed as the sum of dripping induced by the thermal expansion of the material and by gravity, is minimized. The expansion dripping is considered as a measure for an initial melt dripping and the gravity dripping a measure for a long-term melt dripping. In particular, the unwanted oozing of molten build material from the die during traveling of the print head can be minimized or suppressed entirely.
For an analytical modeling, the pressure drop between the internal pressure inside the nozzle and the outside, atmospheric pressure can be calculated using the Hagen-Poiseuille equation with contributions from the nozzle and the die. Likewise, the dripping from the melt compression and via contribution from gravity may be expressed analytically.
In another embodiment of the method, a) for the nozzle having an internal diameter d Noz of ≥ 1.7 mm to ≤ 1.8 mm and the die having an internal diameter d Die of ≥ 0,9 mm to ≤ 1,1 mm: aaa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: T max is ≥ 220 °C to ≤ 230 °C and p max is ≥ 300 kPa to ≤ 330 kPa; aab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: T max is ≥ 220 °C to ≤ 230 °C and p max is ≥ 565 kPa to ≤ 595 kPa; aba) for the mass rate rh being ≥ 75 mg/s to ≤ 85 mg/s: T max is ≥ 235 °C to ≤ 245 °C and p max is ≥ 415 kPa to ≤ 445 kPa; abb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: T max is ≥ 235 °C to ≤ 245 °C and p max is ≥ 765 kPa to ≤ 795 kPa; b) for the nozzle having an internal diameter d Noz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter d Die of ≥ 0,9 mm to ≤ 1,1 mm: baa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: T max is ≥ 220 °C to ≤ 230 °C and p max is ≥ 200 kPa to ≤ 230 kPa; bab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: T max is ≥ 220 °C to ≤ 230 °C and p max is ≥ 380 kPa to ≤ 410 kPa; bba) for the mass rate being ≥ 75 mg/s to ≤ 85 mg/s: T max is ≥ 235 °C to ≤ 245 °C and P max is ≥ 280 kPa to ≤ 310 kPa; bbb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: T max is ≥ 235 °C to ≤ 245 °C and P max is ≥ 510 kPa to ≤ 540 kPa; c) for the nozzle having an internal diameter d Noz of ≥ 1.7 mm to ≤ 1.8 mm and the die having an internal diameter d Die of ≥ 0,3 mm to ≤ 0,5 mm: caa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 1010 kPa to ≤ 1040 kPa; cab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 1735 kPa to ≤ 1765 kPa; cba) for the mass rate rh being ≥ 75 mg/s to ≤ 85 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 2825 kPa to ≤ 2855 kPa; ebb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 4330 kPa to ≤ 4360 kPa; and d) for the nozzle having an internal diameter d Noz of ≥ 2,8 mm to ≤ 2,9 mm and the die having an internal diameter d Die of ≥ 0,3 mm to ≤ 0,5 mm: daa) for the mass rate rh being ≥ 15 mg/s to ≤ 25 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 1010 kPa to ≤ 1040 kPa; dab) for the mass rate rh being ≥ 35 mg/s to ≤ 45 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 1735 kPa to ≤ 1765 kPa; dba) for the mass rate rh being ≥ 75 mg/s to ≤ 85 mg/s: T max is ≥ 250 °C to ≤ 250 °C and P max is ≥ 2765 kPa to ≤ 2795 kPa; dbb) for the mass rate rh being ≥ 155 mg/s to ≤ 165 mg/s: T max is ≥ 250 °C to ≤ 260 °C and P max is ≥ 4215 kPa to ≤ 4245 kPa.
In another embodiment of the method the ratio 1 Noz : D Noz is > 4: 1 to ≤ 7: 1. In another embodiment of the method the build material has a crystallization temperature of ≥ 80 °C to ≤ 85 °C as determined by differential scanning calorimetry according to DIN EN ISO 11357 at a cooling rate of 10 K/min.
In another embodiment of the method the build material has a storage modulus G’ 20 at 20 °C of ≥ 50 MPa to ≤ 60 MPa as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min.
In another embodiment of the method the build material has a storage modulus G’ 100 at 100 °C of ≥ 15 MPa to ≤ 25 MPa as determined by torsional dynamic mechanical analysis according to DIN EN ISO 6721 at a frequency of 1 Hz and a heating rate of 2 K/min.
In another embodiment of the method the build material has a ratio G’ 100 /G’ 20 of ≥ 1:4 to ≤ 1: 1.5.
In another embodiment of the method the build material has a Shore A hardness according to DIN ISO 7619-1 of ≥ 82 to ≤ 87.
In another embodiment of the method the polyurethane is obtainable by the reaction of: a) a polyisocyanate component comprising an aromatic diisocyanate, an aliphatic diisocyanate or a mixture of the aforementioned substances; b) a polyol component comprising poly (tetramethylene ether glycol), polybutylene adipate or a mixture of the aforementioned substances and c) a chain extender component comprising a linear a,co-alkylene diol.
Preferred are molar ratios of chain extenders c) to polyols b) of ≥ 1,5: 1.
In another embodiment of the method the article is a fluid-controlled actuator. Such actuators may be hydraulic or pneumatic soft grippers, for example.
The present invention will be described in greater detail with reference to the following examples and figures without wishing to be limited to them.
FIG. la schematically shows a cross-section of a printing head 100 comprising a nozzle and a die . The length of the nozzle is denoted as Koz and the internal diameter of the nozzle is denoted as d Noz . Likewise, the length of the die is denoted as tie and the internal diameter of the die is denoted as d Die - A chamber within the nozzle is adapted to receive a filament of thermoplastic build material, as will be shown in FIG. 1b. The thermal energy transfer needed to melt the build material takes place via the walls of the nozzle. Therefore, INoz signifies the length of a heating chamber. Heating elements are not depicted.
FIG. lb shows the printing head 100 of FIG. la after having received a filament 200 of thermoplastic build material. The filament 200 has a diameter d Fil which matches d Noz as closely as possible and ideally is equal to d Noz . In the course of a 3D printing operation, filament 200 has been molten. Inside the nozzle the molten material has a maximum melt temperature T max and exerts a maximum pressure p max against the walls of the nozzle.
In examples 1 to 4 the individual contributions of the dripping owing to material expansion in the nozzle and to gravity were calculated for two different filament diameters. In examples 1 and 2, the dimensions of the nozzle and die (cf. FIG. la) were: d Noz = d Fil ; 1 Noz = 11,5 mm; d Die = 1,0 mm and 1 Die = 2,47 mm. In examples 3 and 4, the dimensions of the nozzle and die (cf. FIG. la) were: d Noz = d Fil ; 1 Noz = 11,5 mm; d Die = 0,4 mm and 1 Die = 2,47 mm.
In each of examples 1 to 4, the lowest total melt dripping sum for a given mass rate rh is marked in underlined bold typeface. Then it is easy to identify machine settings such as melt temperatures T max for a desired printing speed (i.e., mass rate).
The build material which was used in the calculations was an aromatic, C4 ester-based thermoplastic polyurethane having a crystallization temperature (DSC according to DIN EN ISO 11357, 10 K/min) of 82 °C and a ratio of storage modulus G’ 100 at 100 °C to storage modulus G’ 20 at 20 °C (DMA according to DIN EN ISO 6721, 1 Hz, 2 K/min) of 55%.
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