3D Printing Resin Composition for Stiff Water-Removable Molds
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Solution Overview
Problem
Existing 3D printing compositions are limited in their ability to form articles with high stiffness and fine features, particularly for molding applications such as thin molds for injection molding, and often fail to provide sufficient mechanical properties.
Innovation Solution
Compositions comprising compounds with specific structures and monomeric curable materials, including acrylates and acrylamides, are used to form 3D articles with enhanced mechanical properties, allowing for the creation of molds that can be easily removed after use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional build materials are used for 3D printing, then the printing process can be completed, but the resulting articles lack sufficient mechanical properties and stiffness for molding applications
Solution Approach 1:
The patent employs composite materials by combining poly(ethylene glycol) diacrylate (PEGDA) with water-soluble polymers such as polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), or starch. This composite approach enables the build material to achieve both sufficient mechanical strength and stiffness while maintaining water solubility for easy mold removal, directly resolving the contradiction between mechanical properties and reliability in molding applications
2Ease of manufacture
If conventional build materials are used, then articles can be formed, but they cannot be removed in a desired manner from molded articles
Solution Approach 1:
The patent utilizes parameter changes by designing the build material with specific chemical composition (PEGDA combined with water-soluble polymers) that changes its solubility parameter. The material transitions from an insoluble cured state during printing to a soluble state after use, enabling easy removal through water dissolution without damaging the molded article, thus resolving the contradiction between ease of manufacture and material loss
3Manufacturing precision
If existing compositions are used for molding applications, then the printing process works, but thin molds with fine features cannot be formed due to insufficient stiffness
Solution Approach 1:
The patent applies local quality by formulating the build material with specific compositional characteristics (PEGDA combined with water-soluble polymers in controlled ratios) that provide enhanced stiffness and dimensional stability in the cured state. This localized material property enhancement enables the formation of thin molds with fine features while maintaining sufficient structural integrity during the molding process, resolving the contradiction between manufacturing precision and strength
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 described compositions enable the production of 3D articles with Young's Modulus greater than 100,000 kPa and facilitate the formation of molds that can be dissolved or dispersed in water, providing improved mechanical properties and ease of mold removal.
Implementation Method 1
selectively curing one or more portions of the composition
Data Source
AI summary
In one aspect, compositions or build materials for use with an additive manufacturing system are described herein. In some embodiments, a composition described herein comprises a compound having the structure of Formula (I) and/or a compound having the structure of Formula (II), wherein the compound having the structure of Formula (I) and/or Formula (II) is present in an amount of 10-35 wt. %, based on the total weight of the composition; and a monomeric curable material having the structure of Formula (III). In some implementations, the monomeric curable material of Formula (III) is present in an amount of 30-50 wt. %, based on the total weight of the composition. In some cases, the composition further comprises an acrylate or acrylamide component. In some instances, the acrylate or acrylamide component is present in an amount of 25-50 wt. %, based on the total weight of the composition.