3D Printing Build Material Composition for Resolution and Strength
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Solution Overview
Problem
Existing 3D printing materials, particularly UV-curable acrylate formulations, often result in parts with high resolution but lack desirable mechanical properties and are prone to fracture or degradation.
Innovation Solution
A polymerizable liquid comprising an acrylate component, a polymeric additive, and a monomeric curing agent that are copolymerizable upon exposure to light, enabling the formation of a copolymer that can further react with crosslinking species to chemically link polymeric networks, enhancing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV-curable acrylate formulations are used for 3D printing, then high resolution is achieved, but mechanical properties are poor and parts are prone to fracture
Solution Approach 1:
The patent uses a composite build material formulation containing acrylate monomer, polymeric additive (such as thermoplastic polymer), and monomeric curing agent. This composite system combines the high resolution capability of UV-curable acrylate with the enhanced mechanical properties provided by the polymeric additive and crosslinked network, resolving the contradiction between resolution and strength.
Solution Approach 2:
The patent modifies the chemical composition parameters of the build material by incorporating specific ratios of acrylate component (50-90 wt%), polymeric additive (5-40 wt%), and monomeric curing agent (1-10 wt%). These parameter changes enable the material to achieve both high resolution and improved mechanical properties through controlled copolymerization and crosslinking.
2Manufacturing precision
If UV-curable acrylate formulations are used for 3D printing, then high resolution is achieved, but parts are prone to fracture or degradation
Solution Approach 1:
The composite material system combines acrylate monomer with polymeric additive and monomeric curing agent to create a crosslinked network structure. This composite approach provides both the high resolution needed for detailed printing and the fracture resistance required for reliable parts, eliminating the trade-off between resolution and reliability.
Solution Approach 2:
The monomeric curing agent is pre-incorporated into the build material formulation before printing. This preliminary action ensures that crosslinking occurs during or after the printing process, creating a mechanically robust network that prevents fracture and degradation before the parts are put into service.
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
The solution results in 3D printed articles with improved mechanical properties such as tensile strength, shear strength, flexibility, and impact resistance, achieved through chemical linking of polymeric networks without the need for added pigments.
Implementation Method 1
the acrylate component and monomeric curing agent are copolymerizable upon exposure to light
Implementation Method 2
the monomeric curing agent can enable further reaction of the copolymer with one or more crosslinking species to chemically link the copolymer with one or more polymeric networks
Data Source
AI summary
Polymerizable liquids are described herein which, in some embodiments, can produce 3D printed articles of high resolution and desirable mechanical properties. In one aspect, a polymerizable liquid comprises an acrylate component, a polymeric additive, and a monomeric curing agent, wherein the acrylate component and monomeric curing agent are copolymerizable upon exposure to light. In being copolymerizable, the acrylate component and monomeric curing agent can form a copolymer. As described father herein, the monomeric curing agent can enable further reaction of the copolymer with one or more crosslinking species to link the copolymer with one more polymeric networks.