Advancements for Increasing Inter-Layer Adhesion in 3D Printing
20 patents in this list
Updated:
Ensuring robust connections between layers in a 3D printed product is one of the primary challenges. Because inadequate layer adhesion might result in layer separation or delamination, printed objects may be less useful and long-lasting.
However, in order to increase layer adhesion and produce more lasting 3D printed goods, various innovative techniques are being explored.
1. Cross-Layer Riveting for Increasing Inter-Layer Adhesion
DANA ITALIA S.R.L., 2023
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.
2. Use of Multihydrazide Compounds to Improve Bonding Between 3D Printed Layers
Hewlett-Packard Development Company, L.P., 2023
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.
3. Solvent-Free Method for Increasing Adhesion Between 3D Printed Resin Layers
SEIKO EPSON CORPORATION, 2021
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.
4. 3D Printing Head with Layer-Texturing Feature for Enhancing Inter-Layer Adhesion
SIGNIFY HOLDING B.V., 2019
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.
5. Temperature Gradient Technique for Better Interlayer Adhesion in FDM 3D Printing
SABIC GLOBAL TECHNOLOGIES B.V., 2018
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.
6. Forming Mechanical Interlocks Between Adjacent Layers of a 3D Printed Object
Empire Technology Development LLC, 2017
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.
7. Use of Transparent Substrate and Pressure Conveyance for Better Layer-to-Layer Bonding
Sakuu Corporation, 2023
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.
8. Enhanced Photocurable Composition for Improved 3D Printing Adhesion
Henkel AG & Co. KGaA, 2022
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.
9. 3D Printing Process for Reinforced Concrete Structures with Embedded Continuous Reinforcement Elements
Peri GmbH, 2021
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.
10. Selective Binding Method for Enhanced Layer Adhesion in 3D Printing
DIGITAL METAL AB, 2021
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.
11. 3D Printed Curable Joint Structures for Enhanced Object Bonding
Wisconsin Alumni Research Foundation, 2020
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.
12. Stress-Relief Cavities for Enhanced Adhesion in 3D Printing on PCBs
SIGNIFY HOLDING B.V., 2020
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.
13. Inkjet Printing and Laser Sintering Method for Enhanced 3D Printed Electronics
FUJI CORPORATION, 2019
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.
14. Selective Deposition of Binder and Part Material for Enhanced Multi-Material 3D Printing
Baker Hughes Incorporated, 2018
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.
15. Enhanced 3D Printing Techniques for Sinterable Materials with Deformation-Resistant Binder Systems
Desktop Metal, Inc., 2018
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.
16. 3D Printing Method with Embedded Objects and Removable Boundary Regions
Xerox Corporation, 2018
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.
17. Integrated Adhesive Printing for Enhanced 3D Printed Structure Assembly
XEROX CORPORATION, 2018
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.
18. Adhesive Layer Technique for Enhanced Surface Structures in 3D Printing
Rakshit Amba, Jai Prashant Amba, 2018
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.
19. 3D Printing Technique for Molded Bodies with Enhanced Decorative Surfaces
LEONHARD KURZ STIFTUNG & CO. KG, 2017
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.
20. Hybrid Additive and Conventional Manufacturing for Enhanced Precision and Strength in 3D Printed Parts
General Electric Company, 2016
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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In order to achieve better inter-layer bonds in 3D printed objects, these techniques involve novel material combinations and printing processes that go beyond the initial layer formation. This opens up new applications and produces stronger printed parts.