Copolymer Support Material for 3D Printing
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Solution Overview
Problem
Current digital manufacturing processes require support materials with improved solubility in mild aqueous solutions while maintaining mechanical strength, thermal stability, and processing characteristics, especially for efficient removal in automated systems.
Innovation Solution
A copolymer comprising carboxyl monomer units from methacrylic acid, phenyl monomer units from styrene, first carboxylate ester monomer units from alkyl methacrylate, and second carboxylate ester monomer units from ethylhexyl acrylate, which provides excellent adhesion, thermal stability, and rapid solubility in alkaline solutions, reducing processing hazards and enhancing workplace safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If support materials are designed for rapid solubility in aqueous solutions, then removal efficiency is improved, but mechanical strength and thermal stability deteriorate
Solution Approach 1:
The invention uses a copolymer comprising four different monomer units (carboxyl monomer units from methacrylic acid, phenyl monomer units from styrene, first carboxylate ester monomer units from alkyl methacrylate, and second carboxylate ester monomer units from ethylhexyl acrylate) to create a support material that combines mechanical strength with rapid solubility. Each monomer unit contributes different properties: carboxyl groups provide solubility in alkaline solutions, phenyl groups provide structural strength, and carboxylate ester groups provide thermal stability while maintaining solubility.
2Loss of time
If support materials are designed for rapid solubility in aqueous solutions, then manufacturing time is reduced, but thermal stability deteriorates
Solution Approach 1:
The copolymer incorporates carboxylate ester monomer units (particularly from ethylhexyl acrylate) that provide thermal stability through their chemical structure, while simultaneously maintaining rapid solubility in alkaline aqueous solutions. The specific combination of monomer units creates a material that can withstand extrusion temperatures (melting between 160-270°C) yet dissolves quickly in mild aqueous solutions after printing.
3Strength
If conventional support materials are used, then mechanical strength is maintained, but solubility in mild aqueous solutions deteriorates
Solution Approach 1:
The invention modifies the chemical composition parameters of the support material by incorporating specific monomer units with carboxyl groups that enhance solubility in mild aqueous solutions while maintaining mechanical strength. The copolymer structure with controlled ratios of different monomer units creates a material that dissolves in alkaline solutions at controlled rates, enabling automated removal processes.
4Productivity
If support materials are designed for automated removal processes, then productivity is improved, but material specifications become more complex
Solution Approach 1:
The copolymer is designed with specific controllable parameters (monomer unit composition, molecular weight, glass transition temperature range) that can be adjusted to optimize both mechanical performance and solubility characteristics for automated removal. The material provides a balanced set of properties: Tg between 90-140°C for proper extrusion behavior, solubility in alkaline solutions for automated washing, and sufficient mechanical strength for support function.
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 copolymer ensures strong and removable support structures with controlled extrusion behavior, rapid dissolution in aqueous solutions, and improved processing safety, increasing production efficiency and reducing exposure to harmful substances.
Implementation Method 1
rapid dissolution in aqueous solutions
Implementation Method 2
at least partially melting a support material... through an extrusion nozzle heated to a temperature of between 160 and 270°C
Data Source
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AI summary
The invention relates to copolymers for use in a digital manufacturing process, in particular support materials for use in a digital manufacturing process comprising such copolymers. More particularly, the invention is directed to a copolymer, a support material based on the said copolymer, the use of the said copolymer in a digital manufacturing process, a method for preparing the said copolymer and a method for building a 3D-model by using a support material comprising the said copolymer.