Active-Energy-Ray-Curable Resin for 3D Printing Support Removal
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Solution Overview
Problem
Existing three-dimensional object forming techniques using photo-curable resins face challenges in achieving good handling properties, object forming accuracy, and shape supporting ability, particularly in removing support parts without damaging the formed shape, especially when dealing with large volumes and complex geometries.
Innovation Solution
An active-energy-ray-curable liquid composition is developed, containing a monomer with hydrogen-bonding capacity and a solvent with similar properties, which, when cured, exhibits a compressive stress of 2.0 kPa or greater and has a water decaying property, enabling easy removal of support parts by water immersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a photo-curable resin composition is used to form support parts with water solubility, then the support parts can be easily removed by water, but the compressive stress and shape supporting ability are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the photo-curable resin by incorporating specific compounds (hydroxyl-terminated polybutadiene, polysiloxane, polyether, or polyester) with controlled molecular weights and ratios. This modifies the cured product's mechanical properties to achieve both water solubility and sufficient compressive stress (≥2.0 kPa), resolving the contradiction between ease of removal and structural strength.
Solution Approach 2:
The patent creates a composite resin system combining multiple components: base resin, hydroxyl-terminated polybutadiene (5-50 parts by weight), polysiloxane (5-50 parts), polyether (5-50 parts), and polyester (5-50 parts). This composite formulation synergistically provides both water solubility for easy removal and adequate compressive stress for shape support during the printing process.
2Ease of operation
If the viscosity of the liquid composition is reduced for better handling, then the handling properties improve, but the object forming accuracy and shape supporting ability deteriorate
Solution Approach 1:
The patent optimizes the viscosity parameter by controlling the molecular weight and concentration of polymeric additives (hydroxyl-terminated polybutadiene, polysiloxane, polyether, polyester) within specific ranges. This achieves a balanced viscosity that ensures proper material flow and handling while maintaining sufficient compressive stress (≥2.0 kPa) for shape support and forming accuracy during inkjet deposition.
3Strength
If the compressive stress is increased to improve shape supporting ability, then the shape supporting ability improves, but the water decaying property and ease of removal deteriorate
Solution Approach 1:
The patent modifies the chemical composition parameters by incorporating water-soluble polymers (hydroxyl-terminated polybutadiene, polysiloxane, polyether, polyester) with specific molecular weights and ratios. This creates a cured product with compressive stress ≥2.0 kPa for adequate shape support while maintaining water solubility for easy removal, resolving the contradiction between strength and ease of removal.
Solution Approach 2:
The patent develops a composite photo-curable resin system combining base resin with specific proportions of water-soluble polymers (5-50 parts by weight each). This composite formulation provides synergistic effects where the cured product achieves both sufficient compressive stress for shape support and water solubility for easy post-processing removal.
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 composition allows for improved handling and object forming accuracy, with support parts that can be easily removed, maintaining the shape and properties of the formed object, even for larger and more complex geometries.
Implementation Method 1
contains a monomer (A) having a hydrogen-bonding capacity and a solvent (B) having a hydrogen-bonding capacity
Implementation Method 2
A cured product obtained by irradiating the active-energy-ray-curable liquid composition with 500 mJ/cm2 of an active energy ray
Data Source
AI summary
Provided is an active-energy-ray-curable liquid composition containing a monomer (A) having a hydrogen-bonding capacity and a solvent (B) having a hydrogen-bonding capacity, wherein the active-energy-ray-curable liquid composition satisfies conditions below, <Conditions> a cured product obtained by irradiating the active-energy-ray-curable liquid composition with 500 mJ/cm2 of an active energy ray is a solid having a compressive stress of 2.0 kPa or greater when compressed by 1% at 25 degrees C., and the cured product has a water decaying property.