Cyclopolymerizable Monomer Ink for 3D Printing
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Solution Overview
Problem
Existing 3D printing inks based on acrylates often produce articles that are rigid, brittle, and have low impact resistance, failing to match the mechanical properties of thermoplastic materials.
Innovation Solution
Development of inks containing a cyclopolymerizable monomer with an acrylate and ethenyl or ethynyl moiety, which are used in combination with oligomeric and monomeric curable materials, photoinitiators, and additives, allowing for improved mechanical properties through specific curing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If prior acrylate-containing inks are used for 3D printing, then articles can be printed with very good resolution, but the resulting articles are rigid, brittle, and have low impact resistance
Solution Approach 1:
The patent changes the chemical composition parameters of the ink by incorporating cyclopolymerizable monomers with specific structural features (Formula I) alongside acrylate monomers. This compositional parameter change enables the cured article to achieve both high printing resolution and improved impact resistance, resolving the contradiction between manufacturing precision and strength.
Solution Approach 2:
The patent creates a composite curing system that combines acrylate polymerization with cyclopolymerization. The ink contains multiple curable components (acrylate monomers and cyclopolymerizable monomers) that work together to form a composite network structure, providing both the resolution benefits of acrylates and the enhanced toughness from cyclopolymerization.
2Manufacturing precision
If prior acrylate-containing inks are used for 3D printing, then articles can be printed with very good resolution, but the resulting articles are rigid and brittle
Solution Approach 1:
The patent modifies the chemical composition of the ink by adding cyclopolymerizable monomers with specific molecular structures (Formula I) that introduce flexibility into the cured network. This parameter change allows the article to maintain printing resolution while achieving improved flexibility and reduced brittleness.
Solution Approach 2:
The patent employs a composite polymer network formed by both acrylate and cyclopolymerization reactions. The dual-curing mechanism creates a composite material structure that combines the dimensional stability and resolution of acrylate networks with the flexibility and toughness of cyclopolymer networks.
3Strength
If inks with higher viscosity are used, then articles may have better mechanical properties, but the printing process becomes slower and more difficult
Solution Approach 1:
The patent carefully balances the viscosity parameter of the ink formulation to achieve optimal printing performance. The cyclopolymerizable monomer composition and concentration are adjusted to provide adequate mechanical properties in the cured article while maintaining low enough viscosity for fast, easy printing processes.
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 inks produce 3D articles with enhanced tensile modulus, tensile strength, elongation, and impact resistance, comparable to thermoplastic materials, while also reducing viscosity for easier and quicker printing.
Implementation Method 1
The cyclopolymerizable monomer comprises an acrylate moiety and an ethenyl or ethynyl moiety... the α-carbon of the acrylate moiety and the α-carbon of the ethenyl or ethynyl moiety may have a 1,5-, 1,6-, 1,7-, or 1,8-relationship
Implementation Method 2
allowing for improved mechanical properties through specific curing processes... at least one photoinitiator
Data Source
Figure 1
AI summary
In one aspect, inks for use with a three-dimensional (3D) printing system are described herein. In some embodiments, an ink described herein comprise 10-70 wt. % or 20-40 wt. % of a cyclopolymerizable monomer, based on the total weight of the ink. The cyclopolymerizable monomer comprises an acrylate moiety and an ethenyl or ethynyl moiety, and the a-carbon of the acrylate moiety and the a-carbon of the ethenyl or ethynyl moiety may have a 1, 5-, 1,6-, 1,7-, or 1,8- relationship. Additionally, an ink described herein can have a viscosity of 1600 centipoise (cP) or less at 30°C, or of 500 cP or less at 30°C and can be used to print a desired 3D article having mechanical properties similar to those of articles formed from thermoplastic materials.