Energy-Pulse Transfer Printing Support Material
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Solution Overview
Problem
Current additive manufacturing processes, such as LIFT, face challenges in producing self-supporting structures with overhangs and undercuts due to the need for support materials that are not metallic and can blend with various printed materials, especially for dental restorations.
Innovation Solution
Development of support materials containing an energy transformation component, a volume expansion component, and a binder, which are applied in a layered process using energy pulses to transfer and solidify on a receiver substrate, allowing for the creation of three-dimensional objects with overhangs and undercuts, particularly suitable for dental restorations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If an absorption layer is provided to absorb laser light and transfer energy to the material to be printed, then the laser energy absorption is improved, but parts of the absorption layer are transferred onto the receiver substrate together with the printing ink
Solution Approach 1:
The patent removes the absorption layer from the system by using a transparent carrier substrate that allows laser light to pass through directly to the material to be printed. This eliminates the harmful transfer of absorption layer material while maintaining effective laser energy absorption through the transparent carrier and into the printed material.
Solution Approach 2:
The transparent carrier substrate acts as an intermediary that transmits laser energy to the material to be printed without being consumed or transferred to the receiver substrate. The carrier substrate mediates between the laser source and the printed material, enabling energy transfer without material contamination.
2Adaptability or versatility
If support materials are used to print self-supporting structures or undercuts, then the ability to produce complex geometries is improved, but the support materials must be removed from the printed body after completion
Solution Approach 1:
The patent uses support materials with specific physical parameters (low surface tension, appropriate viscosity, and phase change properties) that allow them to be easily removed after printing. The support materials are formulated to detach cleanly from the printed body through controlled phase changes or solubility, simplifying the post-processing removal step while enabling complex geometry production.
3Strength
If metallic support materials are used, then the structural support is improved, but the support materials cannot blend with various printed materials especially for dental restorations
Solution Approach 1:
The patent employs support materials formulated as composite systems combining binder polymers with specific functional additives. These composite support materials provide the necessary structural strength while maintaining chemical compatibility and blendability with diverse printed materials, particularly in dental restoration applications where material harmonization is critical.
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
Enables the production of complex three-dimensional structures with overhangs and undercuts by effectively transferring and solidifying support materials, allowing for the integration of various materials and reducing the need for additional absorption layers, thus enhancing the manufacturing of dental restorations.
Implementation Method 1
a volumetric or positional change is induced by a focused laser beam locally in the material to be printed
Implementation Method 2
A part of the material to be printed is evaporated abruptly by the laser energy
Implementation Method 3
The carrier is heated by the laser and the material is indirectly softened or melted
Implementation Method 4
The material to be printed is transferred from the so-called donor or carrier substrate onto the receiver substrate (acceptor)
Data Source
AI summary
A material for use as support material for energy-pulse-induced transfer printing, which contains (a) at least one energy transformation component, (b) at least one volume expansion component and (c) at least one binder and which has a viscosity at 25° C. of from 0.2 Pas to 1000 Pas and a surface tension at 25° C. of from 20 to 150 mN/m. The invention furthermore relates to a process for producing three-dimensional objects using the support material.