Curable Gellant Ink 3D Printing Process

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Solution Overview

Problem

Current 3D printing processes face challenges such as the need for support structures for overhangs, material waste, and slower build speeds, particularly in stereolithography (SLA) and selective laser sintering (SLS), which require additional support materials and post-processing steps.

Innovation Solution

A process using a curable gellant ink with a phase transition temperature, heated above its transition point for deposition and cooling to form a gel layer, where unexposed areas act as support and can be reused, eliminating the need for separate support materials and reducing waste by melting away the build material after object formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate support materials are used in SLA or MJM processes to enable overhangs, then the ability to print complex 3D structures is improved, but the process complexity and post-processing requirements increase

Engineering Contradiction:

Improveability to print complex 3D structuresVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the support structure function with the build material itself by using a single curable gellant ink composition for both purposes. The unreacted ink serves as support while the reacted ink forms the object, eliminating the need for separate support materials and simplifying the overall process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The curable gellant ink composition performs multiple functions: it serves as both the build material that forms the 3D object and the support material that enables overhangs. This multi-functional material eliminates the need for separate support structures and reduces post-processing steps.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate support materials are used and removed post-build, then overhangs can be supported, but material waste and post-processing time increase

Engineering Contradiction:

Improvesupport for overhangsVSAvoidmaterial waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The unreacted curable gellant ink that serves as support material is melted away after the build process and can be recovered and reused for subsequent prints. This reduces material waste compared to traditional support materials that are discarded after a single use.

Inventive Principle:

Principle #34Discarding and recovering

3Device complexity

If powder bed is used as support structure in SLS, then separate support materials are eliminated, but surface finish quality deteriorates

Engineering Contradiction:

Improveelimination of separate support materialsVSAvoidsurface finish quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent uses a curable gellant ink composition that changes phase from liquid to gel upon contact with the substrate. This parameter change allows the material to be deposited as a smooth liquid layer that then solidifies, providing good surface finish while eliminating the need for separate support structures.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If traditional SLA processes are used with support structures, then overhangs can be printed, but build speed decreases due to additional processing steps

Engineering Contradiction:

Improvecapability to print overhangsVSAvoidbuild speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent extracts the support structure removal step from the traditional SLA process by using unreacted ink that can be easily melted away. This eliminates time-consuming post-processing steps like solvent washing while maintaining the capability to print overhangs.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This approach enhances build speed, reduces material waste, and eliminates the need for separate support structures, offering a more efficient and cost-effective 3D printing method by utilizing the gellant ink as both the build material and support for overhangs.

Implementation Method 1

providing a curable gellant ink composition having a phase transition temperature; heating the ink composition to a temperature above the phase transition temperature; depositing the ink composition onto a substrate; wherein upon contact with the substrate the ink composition freezes to provide a gel ink layer

Methodology Applied

Scientific EffectPhase transition: Phase Change

Implementation Method 2

treating at least a portion of the gel ink layer whereby treated gellant ink reacts to form a three-dimensional object

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS10174205B2Printing process

Publication Date: 2019.01.08 GENESEE VALLEY INNOVATIONS LLC

AI summary

A process including providing a curable gellant ink composition having a phase transition temperature; heating the ink composition to a temperature above the phase transition temperature; depositing the ink composition onto a substrate; wherein upon contact with the substrate the ink composition freezes to provide a gel ink layer; treating at least a portion of the gel ink layer whereby treated gellant ink reacts to form a three-dimensional object and wherein untreated gellant ink does not react and remains in gellant form; optionally, wherein the unreacted gellant ink provides a support structure for overhang portions of the three-dimensional object.