3D Printed Soft Tissue Materials With UV-Cured Composite Structure
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Solution Overview
Problem
Current additive manufacturing techniques are unable to produce 3D objects with portions that mimic the mechanical and visual properties of soft bodily tissues, as existing materials harden to a Shore hardness exceeding the characteristics of soft tissues, leading to issues like low tensile strength, tear resistance, and dimensional instability.
Innovation Solution
The method involves dispensing elastomeric curable formulations with specific Shore A hardness lower than 10 or Shore 00 hardness lower than 40, combined with non-curable polymeric materials, to form objects with fibrous patterns and shell coatings, using 3D inkjet printing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional photopolymerizable materials are used in additive manufacturing, then the material can be cured and solidified to form structural layers, but the hardened material exhibits Shore hardness exceeding soft tissue characteristics, resulting in poor tensile strength and tear resistance
Solution Approach 1:
The patent changes the material parameters by using non-curable polymeric materials with specific viscosity ranges (50-5000 cP) and molecular weights (1000-100,000 Daltons), and by controlling the ratio of curable to non-curable materials (1:9 to 9:1), achieving a hardened material with Shore A hardness of 10-90 that mimics soft tissue properties while maintaining dimensional stability
Solution Approach 2:
The patent creates a composite material system combining curable photopolymerizable materials with non-curable polymeric materials. This composite approach allows the curable component to provide structural integrity and dimensional stability upon UV curing, while the non-curable component contributes to soft tissue-like mechanical properties including tensile strength and tear resistance, achieving a balance between these conflicting requirements
2Strength
If gel-like materials are used to achieve soft tissue-like properties, then the material exhibits low viscosity and softness, but the material lacks sufficient tear resistance and dimensional stability
Solution Approach 1:
The patent optimizes material parameters by selecting non-curable polymeric materials with viscosity between 50-5000 cP and molecular weight between 1000-100,000 Daltons, which provides sufficient tear resistance while maintaining dispensability during the printing process. The controlled ratio of curable to non-curable materials (1:9 to 9:1) ensures the composite material remains manufacturable
Solution Approach 2:
The patent applies different material properties to different functional requirements: the curable component provides local structural support and dimensional stability where needed, while the non-curable component provides local softness and tear resistance, creating a material with spatially differentiated properties that satisfies both manufacturing and performance requirements
3Reliability
If hard materials are used to ensure dimensional stability, then the material maintains structural integrity, but the material fails to mimic the mechanical properties of soft bodily tissues
Solution Approach 1:
The patent employs a composite material system where curable photopolymerizable materials provide dimensional stability and structural integrity upon UV curing, while non-curable polymeric materials contribute soft tissue-like mechanical properties. This composite approach allows the material to simultaneously achieve both dimensional stability and soft tissue-mimicking characteristics
Solution Approach 2:
The patent achieves the desired balance by controlling the ratio of curable to non-curable materials (1:9 to 9:1) and selecting materials with specific parameters (viscosity 50-5000 cP, molecular weight 1000-100,000 Daltons), resulting in hardened material with Shore A hardness of 10-90 that maintains both dimensional stability and soft tissue-like mechanical properties
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 method achieves 3D objects with mechanical and visual properties resembling soft bodily tissues, providing sufficient tear resistance, dimensional stability, and visual resemblance, while avoiding the limitations of gel-like materials.
Implementation Method 1
The curable material may be any photopolymerizable (photocurable) material, and the curing condition typically comprises a curing energy, and is typically radiation, for example, UV radiation
Data Source
AI summary
Methods of fabricating three-dimensional objects featuring properties of a soft bodily tissue and three-dimensional objects featuring properties of a soft bodily tissue or of an organ comprising same are provided.