Dental Prosthesis Resin Formulation for UV LED Curing Stability
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Solution Overview
Problem
Current additive manufacturing technologies using UV LED irradiation sources face limitations due to the incompatibility of certain photoinitiators, leading to issues such as increased yellow hue, reduced mechanical stability, and increased water absorption in cured materials, and require custom-synthesized materials with slow reaction rates and high viscosity for denture production.
Innovation Solution
A novel modeling material formulation comprising specific components like di-functional aliphatic urethane (meth)acrylate, micron-sized particles, and ethoxylated aromatic (meth)acrylate, along with a support material formulation, to enhance mechanical properties and compatibility with UV LED irradiation, allowing for efficient production of denture structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-synthesized materials are used for denture production, then biocompatibility is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent modifies the chemical composition parameters of commercial photocurable materials by selecting specific photoinitiators (camphorquinone, Irgacure 2959, Irgacure 819) and adjusting monomer/oligomer ratios to achieve biocompatibility without custom synthesis. This resolves the contradiction by achieving reliable biocompatible materials through parameter optimization rather than complex custom material development.
2Use of energy by moving object
If UV LED irradiation is used for curing, then energy efficiency is improved, but material compatibility is worsened due to photoinitiator limitations
Solution Approach 1:
The patent introduces specific photoinitiators as intermediaries that bridge UV LED irradiation and material curing. By selecting photoinitiators with absorption spectra matching UV LED emission (camphorquinone for 405nm LEDs, Irgacure 2959 for 385nm LEDs), the system achieves both energy efficiency of UV LEDs and material compatibility through the mediating role of these photoinitiators.
Solution Approach 2:
The patent changes the spectral parameters of the curing system by matching photoinitiator absorption maxima with UV LED emission wavelengths. This parameter optimization enables UV LED energy efficiency while maintaining broad material compatibility across different denture components.
3Strength
If high filler content is used in modeling material, then mechanical strength is improved, but viscosity increases leading to printing difficulties
Solution Approach 1:
The patent optimizes the particle size parameter of fillers (1-100 micrometers, preferably 5-50 micrometers) and the viscosity parameter of the base resin to maintain printability while achieving sufficient mechanical strength. By controlling these parameters, the system incorporates 30-80 wt% filler without compromising dispensability through inkjet print heads.
Solution Approach 2:
The patent applies different filler types and sizes to different regions of the denture structure. For example, larger fillers (50-100 micrometers) are used in the denture base where high strength is needed, while smaller fillers (1-10 micrometers) are used in tooth structures where smooth surface finish is critical. This local optimization resolves the contradiction between strength and printability.
4Productivity
If fast-curing materials are used, then productivity is improved, but yellow hue and reduced mechanical stability occur
Solution Approach 1:
The patent uses composite photoinitiator systems combining multiple photoinitiators with different absorption characteristics (camphorquinone, Irgacure 2959, Irgacure 819) to achieve fast curing without yellowing. The composite system captures a broader spectrum of UV LED light, enabling complete polymerization at higher speeds while maintaining material stability and color neutrality.
Solution Approach 2:
The patent optimizes the concentration parameters of photoinitiators (0.1-5 wt%) and the molecular weight parameters of monomers/oligomers to achieve fast curing rates while preventing yellow hue formation. By carefully controlling these parameters, the system maintains mechanical stability even at accelerated curing speeds.
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 formulation achieves improved mechanical stability, reduced yellow hue, and enhanced reaction rates, producing denture structures that meet ISO standards with biocompatibility and desired mechanical properties.
Implementation Method 1
a photoinitiator, and at least one of a (meth)acrylate monomer (A) having one or more ether bonds and two (meth)acryloyloxy groups in one molecule and having a defined Mw, a (meth)acrylate monomer (B) having a ring structure other than an aromatic ring and one (meth)acryloyloxy group in one molecule and having a defined Mw, a (meth)acrylate monomer (C) having a hydrocarbon skeleton and two (meth)acryloyloxy groups in one molecule and having a defined Mw, and a (meth)acrylate monomer (D) having one or more aromatic rings and one (meth)acryloyloxy group in one molecule and having a Mw
Data Source
AI summary
Modeling material formulations usable in additive manufacturing of a denture structure, and additive manufacturing methods employing same are provided. Kits comprising the modeling material formulation, optionally in combination with a support material formulation, are also provided.