Crosslinkable Polymers for 3D Printing High-Aspect-Ratio Structures
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Solution Overview
Problem
Conventional 3D printing methods face challenges in producing high-aspect-ratio structures due to instabilities from surface tension and gravity, limiting the creation of complex geometries.
Innovation Solution
The use of a composition comprising a polymer with dormant functional groups, such as thiocarbonylthio, alkoxyamine, or cobalt-carbon bonds, which undergo controlled radical polymerization and are injected into a yield stress material, allowing for crosslinking and formation of freestanding three-dimensional structures without the need for support materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional 3D printing methods are used to deposit layers of material, then a wide variety of structures can be fabricated, but high-aspect-ratio structures with complex geometries cannot be produced due to instabilities from surface tension and gravity
Solution Approach 1:
The patent changes the physical and chemical parameters of the printed material by using a polymer composition with controlled radical polymerization capability and dormant functional groups. This allows the material to transition from a viscous state during printing to a crosslinked gel state after printing, enabling high-aspect-ratio structures to be formed without collapsing under gravity or surface tension.
Solution Approach 2:
The patent employs a composite material system consisting of a polymer with dormant functional groups (such as thiocarbonylthio, alkoxyamine, or cobalt-carbon bonds) combined with a crosslinking agent and an initiator. This composite formulation enables the material to exhibit both fluidity during deposition and structural integrity after crosslinking, resolving the contradiction between fabricating complex geometries and maintaining manufacturing precision.
2Ease of manufacture
If conventional 3D printing methods are used, then simple structures can be produced, but complex geometries with high aspect ratios face instabilities from surface tension and gravity
Solution Approach 1:
The patent applies preliminary action by incorporating dormant functional groups into the polymer before printing, which remain inactive during the fabrication process but are activated afterward through crosslinking. This preliminary preparation allows the material to be easily deposited without immediate structural constraints, while ensuring reliability is established after printing through controlled crosslinking of the dormant groups.
Solution Approach 2:
The patent utilizes parameter changes by controlling the transition of the polymer from an uncrosslinked viscous state during manufacturing to a crosslinked gel state for structural reliability. The dormant functional groups enable this parameter transition without interfering with the ease of the manufacturing process itself, as crosslinking occurs after the structure is formed.
3Manufacturing precision
If polymers with dormant functional groups are used and injected into yield stress material, then crosslinking can occur to form freestanding three-dimensional structures, but the process requires specific composition and crosslinking conditions
Solution Approach 1:
The patent employs an intermediary approach by using a yield stress material as a medium that facilitates the injection and crosslinking process. The yield stress material acts as a temporary matrix that allows the polymer composition to be deposited in complex geometries and then crosslinks within this matrix to form freestanding structures, simplifying the overall process despite the specialized composition requirements.
Solution Approach 2:
The patent applies self-service by incorporating all necessary components (polymer with dormant groups, crosslinking agent, and initiator) into a single injectable composition. This self-contained formulation eliminates the need for separate crosslinking steps or additional materials, reducing device complexity while maintaining manufacturing precision for freestanding structure formation.
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
Enables the efficient production of complex geometries and high-aspect-ratio structures by leveraging controlled radical polymerization and yield stress materials, reducing manufacturing time and costs while maintaining structural integrity.
Implementation Method 1
the polymer comprises one or more dormant functional groups... the one or more dormant functional groups comprise a thiocarbonylthio group, an alkoxyamine group, a halogen, and/or a cobalt-carbon bond... the method further comprises crosslinking the polymer to form a crosslinked polymeric structure
Data Source
AI summary
Described herein are embodiments of compositions and methods relating to three-dimensional (3D) printing. Some embodiments are directed to a composition comprising a polymer with one or more dormant functional groups. According to some embodiments, the polymer may be formed through a controlled radical polymerization method. Some embodiments are directed to a composition comprising a polymer with one or more pendent crosslinkable groups. In some cases, the composition may be used as an “ink” for 3D printing. For example, the composition may be injected into a medium. The composition and/or medium may, in some embodiments, further comprise an initiator and/or a crosslinker. After injection of the composition into the medium, the one or more dormant functional groups and/or one or more pendent crosslinkable groups may be activated, and the polymer may be crosslinked. In certain cases, the crosslinked polymer may be removed from the medium to produce a freestanding three-dimensional structure.