Dual-Cure 3D Polymeric Structures via Transimidization
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Solution Overview
Problem
Current 3D printing technologies face limitations in the mechanical properties and surface finish of manufactured objects, despite advancements in speed and precision.
Innovation Solution
A dual-cure method involving a curable resin composition combining an end-capped, imide-terminated prepolymer with photopolymerizable olefinic monomers and a diamine, where the composition is irradiated to polymerize and then thermally treated to facilitate a transimidization reaction, releasing end caps and enhancing mechanical properties and surface characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional UV-curable liquid resin is used for 3D printing, then the manufacturing process is simple and fast, but the mechanical properties and surface finish of the manufactured object are poor
Solution Approach 1:
The curing process is divided into two distinct stages: first, UV irradiation to polymerize the olefinic monomer and form a scaffold structure; second, thermal treatment to enable transimidization reaction between the prepolymer and diamine. This segmentation allows each curing mechanism to optimize different aspects of the final material properties without interfering with the other.
Solution Approach 2:
The resin composition is designed as a composite system containing four key components: end-capped imide-terminated prepolymer, photopolymerizable olefinic monomer, photoinitiator, and diamine. This composite approach combines the advantages of photopolymerization (fast initial structure formation) and thermal curing (superior mechanical properties and surface finish) to overcome the limitations of traditional single-cure systems.
2Manufacturing precision
If traditional single-cure UV resin is used, then the manufacturing process is fast, but the surface finish is poor
Solution Approach 1:
The UV irradiation step performs a preliminary action by polymerizing the olefinic monomer to form a stable scaffold structure that defines the 3D object's geometry. This preliminary structuring allows the subsequent thermal treatment to focus on optimizing surface finish and mechanical properties without compromising the object's dimensional integrity, thereby reducing overall manufacturing time despite the two-stage process.
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 method produces 3D objects with superior mechanical properties and optimal surface finish, addressing the limitations of existing technologies.
Implementation Method 1
irradiating the resin composition under conditions effective to polymerize the at least one olefinic monomer and provide a polyolefin within a scaffold that comprises the prepolymer and the polyolefin with the diamine physically trapped therein
Implementation Method 2
thermally treating the irradiated composition at a temperature effective to cause a transimidization reaction to occur between the prepolymer and the diamine
Data Source
AI summary
A dual-cure method for forming a solid polymeric structure is provided. An end-capped, imide-terminated prepolymer is combined with at least one photopolymerizable olefinic monomer, at least one photoinitiator, and a diamine, to form a curable resin composition, which, in a first step, is irradiated under conditions effective to polymerize the at least one olefinic monomer, thus forming a scaffold composed of the prepolymer and the polyolefin with the diamine trapped therein. The irradiated composition is then thermally treated at a temperature effective to cause a transimidization reaction to occur between the prepolymer and the diamine, thereby releasing the end caps of the prepolymer and providing the solid polymeric structure. A curable resin composition comprising an end-capped, imide-terminated prepolymer, at least one photopolymerizable olefinic monomer, at least one photoinitiator, and a diamine, is also provided, as are related methods of use.