3D Printing Ink Set for Soft Object Gelation Accuracy

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Solution Overview

Problem

Existing 3D printing methods struggle to produce complex-shaped three-dimensional objects made of soft materials with good fabrication accuracy, as bioinks often flow out or deform under gravity before gelling.

Innovation Solution

A method involving the use of a model material ink containing a crosslinkable polymer and a support material ink, where one ink includes a hydrogen peroxide decomposer and the other contains hydrogen peroxide or a hydrogen peroxide donor, allowing the crosslinkable polymer to gel through hydrogen peroxide decomposition, thereby producing complex-shaped objects with improved accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If bioink is used for 3D printing to produce complex-shaped three-dimensional objects, then the objects can be formed with desired shapes, but the bioink flows out or deforms under gravity before gelling, resulting in poor fabrication accuracy

Engineering Contradiction:

Improvecomplex shapeVSAvoidfabrication accuracy

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The support material ink is discharged beforehand to form a temporary support structure that maintains the shape of the model material ink before crosslinking occurs. This preliminary structural support prevents deformation under gravity during the gelling process, enabling complex shapes to be formed with high fabrication accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support material acts as an intermediary substance that temporarily supports the model material ink during the crosslinking process. This intermediary structure prevents the bioink from flowing or deforming, and is subsequently removed after the model material ink has gelled, leaving the desired complex shape with high precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the crosslinking reaction is accelerated to prevent deformation, then fabrication accuracy improves, but the support material may interfere with the crosslinking process

Engineering Contradiction:

Improvefabrication accuracyVSAvoidcrosslinking reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The inkjet system is divided into separate nozzles for model material ink and support material ink, allowing independent control and discharge of each ink type. This segmentation ensures that the support material and model material ink are discharged in a controlled sequence and mixture ratio, preventing interference with the crosslinking reaction while maintaining fabrication accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The discharge parameters of the support material ink and model material ink are precisely controlled, including discharge timing, mixture ratio, and positioning. By optimizing these parameters, the support material provides necessary structural support without interfering with the crosslinking reaction, ensuring both fabrication accuracy and crosslinking reliability.

Inventive Principle:

Principle #35Parameter changes

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

This method enables the production of complex-shaped three-dimensional objects with enhanced fabrication accuracy by preventing deformation and ensuring precise structure formation.

Implementation Method 1

one of the model material ink (a) and the support material ink (b) further contains a hydrogen peroxide decomposer and the other of the model material ink (a) and the support material ink (b) further contains hydrogen peroxide or a hydrogen peroxide donor, and the discharged hydrogen peroxide decomposer decomposes the discharged hydrogen peroxide to crosslink the crosslinkable polymer

Methodology Applied

Scientific EffectHydrogen peroxide decomposition: Decomposition (biological)

Implementation Method 2

the discharged hydrogen peroxide decomposer decomposes the discharged hydrogen peroxide to crosslink the crosslinkable polymer

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 3

the discharged hydrogen peroxide decomposer decomposes the discharged hydrogen peroxide to crosslink the crosslinkable polymer, thereby fabricating a three-dimensional object

Methodology Applied

Scientific EffectGelation: Gel

Data Source

PatentUS20250375936A1Method for manufacturing three-dimensional object and ink set for manufacturing three-dimensional object

Publication Date: 2025.12.11 NAGASE CHEMTEX CORPORATION

AI summary

The present invention provides a method for producing a three-dimensional object and an ink set for producing a three-dimensional object which can even produce, for example, a complex-shaped three-dimensional object made of a soft material with good fabrication accuracy. The present invention relates to a method for producing a three-dimensional object, including: individually discharging (a) a model material ink containing a crosslinkable polymer and (b) a support material ink containing a support material; and removing an object of the support material ink after the crosslinkable polymer is crosslinked, wherein one of the model material ink (a) and the support material ink (b) further contains a hydrogen peroxide decomposer and the other of the model and support material inks further contains hydrogen peroxide or a hydrogen peroxide donor, and the discharged hydrogen peroxide decomposer decomposes the discharged hydrogen peroxide to crosslink the crosslinkable polymer, thereby fabricating a three-dimensional object.