3D Printing Build Material With Solid Reactive Component
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Solution Overview
Problem
Current 3D printing materials lack sufficient stiffness and mechanical integrity for engineering applications, particularly in terms of tensile modulus and strength, which limits their usability in producing high-quality, durable parts.
Innovation Solution
A build material comprising an oligomeric curable material, a reactive component that is solid and substantially crystalline at 25°C, and a diluent, where the reactive component contains chemical moieties polymerizable with the oligomeric curable material and/or the diluent, offering a tensile modulus of 1500 to 2200 MPa when cured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional 3D printing materials are used, then the printing process is simple and materials are easily available, but the tensile modulus and mechanical strength are insufficient for engineering applications
Solution Approach 1:
The patent employs composite materials by combining multiple components with distinct functions: oligomeric curable material provides the base polymer matrix, reactive component (solid at 25°C) contributes to crosslinking and mechanical strength, and diluent adjusts viscosity for jetting. This multi-component composite approach enables the cured material to achieve high tensile modulus (1500-2200 MPa) suitable for engineering applications while maintaining processability during printing.
Solution Approach 2:
The patent utilizes parameter changes by controlling the physical state of the reactive component (solid at 25°C) and its phase transition behavior. The material formulation leverages temperature-dependent viscosity changes to enable jetting at elevated temperatures while maintaining structural integrity during curing. The specific parameter range of tensile modulus (1500-2200 MPa) represents a targeted parameter change achievement.
2Strength
If the reactive component is solid at 25°C to enhance stiffness, then the material requires heating for jetting which increases energy consumption
Solution Approach 1:
The patent exploits phase transitions by designing a material system where the reactive component transitions from solid at ambient temperature to liquid at jetting temperature, and then undergoes chemical curing to form a rigid network. The oligomeric curable material and reactive component form a jettable composition at elevated temperature that solidifies upon cooling and curing, enabling the material to be pumped and jetted in liquid form while delivering solid mechanical properties in the final part.
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 build material provides high stiffness and mechanical integrity, enabling the production of three-dimensionally printed articles with enhanced tensile strength, break elongation, and thermal stability, suitable for various engineering applications.
Implementation Method 1
the reactive component comprises at least one chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material and/or the at least one diluent
Data Source
AI summary
In one aspect, build materials operable for use in 3D printing systems are described herein. In some embodiments, a build material comprises an oNgomeric curable material, a reactive component that is solid at 25 °C, and at least one diluent, wherein the reactive component comprises at least one chemical moiety that Is polymerizabie with a chemical moiety contained in the oligomeric curable material and /or the at least one diluent.