Enhancing Inter-Layer Adhesion in 3D Printing

A method for 3D printing multi-layer structures with improved interlayer adhesion to prevent delamination. The method involves creating cavities that cross multiple layers during printing and then filling the cavities with a second material to form rivets perpendicular to the layers. The rivets compress the surrounding layers as they cool and contract, increasing adhesion.

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Improving the tensile strength of 3D printed green bodies to prevent damage during transportation and handling prior to fusing. The method involves selectively applying an adhesion promoter containing multihydrazide compounds like adipic dihydrazide to the binder fluid used in 3D printing. The multihydrazide adhesion promoter enhances the bonding between layers of particulate build material when forming the green body.

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Method for manufacturing a three-dimensional shaped object with high adhesion between layers without using solvents. The method involves shaping a first layer, cutting it, heating it to a temperature below the resin's glass transition temperature, and then shaping subsequent layers on top. The heating step increases adhesion between the layers.

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Printing head for 3D printers that improves adhesion between layers of printed objects. The nozzle of the head includes a texturing member that protrudes from the main surface of the printed layer. These protrusions increase the contact surface area between layers, improving adhesion strength. The textured layer interfaces lock together better when subsequent layers are printed on top. The protrusions can be clamping features that grip the next layer.

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A method to improve interlayer adhesion in 3D printed objects made by fused material extrusion, e.g., FDM. The method involves extruding adjacent layers at different temperatures. The temperature difference between layers should be at least 5°C. This sequence of alternating temperatures enhances bonding between layers to improve the overall strength of the printed object. The layers are fused together after extrusion to form the final article.

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A feedstock for additive manufacturing that enables strong interlayer bonding in 3D printed objects. The feedstock contains removable capsules that, when extracted after printing, leave voids on the surface of the solidified layer. The voids are then filled by the next layer's material, forming mechanical interlocks between layers. This provides enhanced adhesion compared to regular printing.

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An improved method for layer-to-layer bonding in additive manufacturing ensures reliable, uniform bonding of new layers to previously processed layers. The method involves using a transparent substrate between the new uncured layer and the previously cured layer and curing the new layer by applying energy through the substrate to simultaneously cure and bond the new layer to the stack. A flexible pressure conveyance media is then applied to the substrate to uniformly compress the new layer onto the stack during curing.

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Method for performing additive manufacturing using a photocurable composition to form a three-dimensional part. The method involves providing a non-flowable photocurable composition in a reservoir, heating it to a temperature to make it flowable, and then exposing it to radiation to initiate polymerization. This allows the formation of a photoplastic material with improved properties compared to existing photopolymers.

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3D printing of reinforced concrete structures using a process that allows for high-strength reinforcement without the need for complex and expensive formwork. The process involves printing layers of concrete with embedded reinforcement elements that are rigidly connected to adjacent layers. The reinforcement elements are printed in a way that they extend beyond the current layer and are connected to the next layer. This allows for continuous reinforcement throughout the structure.

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A 3D printing method that enables high-accuracy manufacturing of complex objects by selectively binding regions of each layer together. The method involves depositing layers of construction material and binder onto a platform, with the binder selectively bound to specific regions of each layer. This allows the layers to be stacked and bound together to form the final object.

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3D printing a joint structure that can be cured to bond to objects. The joint structure is formed by 3D printing a lattice or honeycomb structure with curable material in a curable state. The joint structure is then positioned in contact with an object and cured to form a bond. The curable material can be matched with the object to form a chemical bond. This allows for complex joint structures to be formed that can bond to objects with high strength.

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3D printing structures directly onto printed circuit boards (PCBs) to avoid buckling and improve adhesion. The PCB has cavities on its surface that form a cavity structure. An adhesion layer is placed over the cavities. The 3D printed structure is then placed over the adhesion layer. The cavities in the adhesion layer release stress and prevent buckling.

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Manufacturing method for three-dimensional electronic devices using inkjet printing and laser sintering to form multiple layers of cross sections. The method involves printing each layer cross section using multiple types of materials and then solidifying each layer by exposing it to light energy. This allows forming and solidifying each layer in the same position without transferring the work, minimizing deformation and defects.

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Additive manufacturing of multi-material parts using a binder and part material that can be selectively deposited to a growing part. The binder and part material are separately applied through separate print heads. The binder is applied to the part to bind it together while the part material is applied to the part to form the desired structure. The binder can be activated by light, temperature, or other stimuli.

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Additive manufacturing techniques for fabricating objects with sinterable build materials that can be debound and sintered to form a final part. The techniques involve fabricating a net shape object from a powdered material with a binder system that resists deformation. An interface layer is applied to the object surface to prevent bonding during sintering. The object is then processed to form the final part.

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3D printing method to form a build structure with embedded 3D objects surrounded by a support matrix and separated by boundary regions. The method involves dispensing three different materials to form the build structure. The first material forms the 3D objects, the second material forms the support matrix, and the third material forms the boundary regions. The boundary regions are arranged to separate the embedded 3D objects. The boundary regions are made of a material that can be softened or melted during a subsequent separation step to remove them from the build structure.

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3D printing structures and assembling them using adhesives that are printed along with the structure. The 3D printer can print the structure and adhesive layers simultaneously. This allows precise placement of the adhesive and eliminates the need for manual application. The adhesive can be an epoxy, polyurethane, or other adhesive that can be cured. The adhesive can be printed as a liquid and cured to form a solid bond.

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3D printing method that allows creating structures and effects on surfaces using a combination of adhesive layers and compatible layers. The adhesive layers are applied to the surface to bond subsequent layers. The compatible layers are then deposited on the adhesive layers to create the desired structure or effect. The method involves preparing the surface with adhesive layers, depositing compatible layers, and then 3D printing on the prepared surface.

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Producing a molded body with a decorative surface layer using 3D printing. The molded body has a plastic molding compound applied to a foil ply using a 3D printer. The foil ply can have a decorative or functional layer. The plastic molding compound is applied layer-by-layer to the foil ply to form the molded body surface. The foil ply can have an adhesion-promoter layer to securely bond the plastic to the foil ply. The foil ply can be a transfer foil or lamination foil. The plastic molding compound can be applied to the foil ply before or after it is attached to a support element.

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Hybrid additive manufacturing methods that combine additive manufacturing with conventional manufacturing techniques to produce complex parts with high precision and strength. The hybrid method involves building a green state additive structure using additive manufacturing, then joining it to a base structure using conventional joining techniques like welding or brazing. The green state structure is a temporary intermediate form that can be easily manipulated before being joined to the base structure. This allows for precise and complex shapes that are difficult or impossible to achieve with conventional manufacturing methods.

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