Cyclopolymerizable Inks 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 achieve mechanical properties similar to those of thermoplastic materials.
Innovation Solution
Development of inks containing cyclopolymerizable monomers with specific structures, such as those with 1,5-, 1,6-, 1,7-, or 1,8- relationships between ethenyl or ethynyl moieties, along with oligomeric and monomeric curable materials, photoinitiators, and additives, which are formulated to improve mechanical properties and reduce viscosity, enabling better printing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If acrylate-containing inks are used for 3D printing, then good resolution is achieved, but the articles become rigid, brittle, and have low impact resistance
Solution Approach 1:
The patent uses composite materials by combining cyclopolymerizable monomers with specific molecular structures (containing both vinyl and ethynyl groups) with oligomeric curable materials. This composite approach creates articles that maintain the resolution benefits of acrylate printing while achieving improved mechanical properties including higher impact resistance, tensile strength, and elongation comparable to thermoplastic materials.
Solution Approach 2:
The patent changes the chemical parameters of the ink composition by introducing cyclopolymerizable monomers with specific structural characteristics (1,5-, 1,6-, 1,7-, or 1,8-relationship between ethenyl/ethynyl moieties). This parameter change in the monomer structure enables the formation of articles with superior mechanical properties while maintaining printability and resolution.
2Strength
If cyclopolymerizable monomers are added to improve mechanical properties, then impact resistance and tensile strength increase, but viscosity may increase affecting printability
Solution Approach 1:
The patent carefully controls the viscosity parameter by selecting cyclopolymerizable monomers with specific molecular weights and structures. The monomers are designed to have viscosities that allow easy jetting through print heads while still providing the desired mechanical property improvements when cured.
Solution Approach 2:
The patent uses oligomeric curable materials as intermediaries that bridge the properties of low-viscosity monomers and high-strength polymers. These oligomers help maintain fluidity for printing while contributing to the final mechanical strength and elongation properties of the cured articles.
3Ease of operation
If ink viscosity is reduced for easier jetting, then printability improves, but mechanical properties of cured articles may be compromised
Solution Approach 1:
The patent optimizes the viscosity parameter of the ink formulation to enable easy jetting through standard print heads. This is achieved by selecting cyclopolymerizable monomers and oligomeric curable materials with appropriate molecular weights and fluidity characteristics that do not compromise the final tensile strength and mechanical properties after curing.
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 new inks produce articles with enhanced mechanical properties, including improved impact resistance, tensile strength, and elongation, while maintaining reduced viscosity for easier and faster printing across various 3D printing technologies like SLA, DLP, and MJP.
Implementation Method 1
inks described herein can be used to print articles with improved mechanical properties... The cyclopolymerizable monomer comprises a first ethenyl or ethynyl moiety and a second ethenyl or ethynyl moiety
Implementation Method 2
Additionally, an ink described herein may comprise at least one photoinitiator... selectively applying energy to the ink in the container to solidify at least a portion of a first fluid layer of the ink
Data Source
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 comprises 10-70 wt. % cyclopolymerizable monomer, based on the total weight of the ink. The cyclopolymerizable monomer comprises a first ethenyl or ethynyl moiety and a second ethenyl or ethynyl moiety. Additionally, the α-carbon of the first ethenyl or ethynyl moiety and the α-carbon of the second ethenyl or ethynyl moiety have a 1,5-, 1,6-, 1,7-, or 1,8-relationship.