High-Refractive Photo-Curable Resin for Precise Ceramic 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies face challenges in effectively using ceramic and metal fillers due to their high refractive indices, leading to light scattering and difficulty in creating sharp edges or hollow bodies, and current solutions suffer from poor decomposition, high viscosity, and toxicity issues.
Innovation Solution
A photo-curable composition comprising monomers with a high refractive index, a cross-linker, and a plasticizer, along with a photo-initiator, scaffold particles, and a dispersant, is used to control light scatter and enhance printing precision, allowing for the creation of inorganic structures like ceramics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high refractive index ceramic and metal fillers are used in 3D printing, then the refractive index of the composite material is improved, but light scattering increases causing uncontrolled polymerization and poor printing precision
Solution Approach 1:
The patent introduces a refractive index matching layer or intermediate medium between the UV light source and the high refractive index fillers. This intermediary component reduces the refractive index contrast, thereby minimizing light scattering while allowing the high refractive index fillers to maintain their optical properties in the final printed structure.
Solution Approach 2:
The patent modifies the optical parameters of the resin matrix by adjusting its refractive index to better match that of the ceramic or metal fillers. This parameter change reduces the refractive index difference, thereby decreasing light scattering and improving printing precision while maintaining the desired high refractive index characteristics.
2Quantity of substance
If conventional resin formulations are used with high refractive index fillers, then the filler loading can be increased, but viscosity increases making the composition difficult to process
Solution Approach 1:
The patent employs a composite resin formulation combining multiple resin components with different rheological properties. This composite approach allows high filler loading while maintaining processable viscosity levels, as the different resin components work synergistically to balance filler suspension and flow characteristics.
Solution Approach 2:
The patent adjusts the chemical composition and molecular weight distribution of the resin matrix to optimize viscosity. By changing these parameters, the formulation can accommodate high filler loading while maintaining adequate flow properties for 3D printing processes.
3Temperature
If conventional binders are used to achieve high refractive index, then the refractive index contrast is reduced, but decomposition performance deteriorates leaving excessive ash or soot
Solution Approach 1:
The patent uses a composite binder system combining organic and inorganic components. The inorganic portion maintains refractive index contrast while the organic portion is designed for complete decomposition, thereby reducing ash and soot formation. This composite approach allows simultaneous optimization of optical properties and decomposition performance.
Solution Approach 2:
The patent modifies the chemical composition of the binder to achieve complete decomposition at printing temperatures. By selecting specific chemical structures and compositions, the binder decomposes fully without leaving residual ash or soot, while maintaining the necessary refractive index contrast for optical applications.
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 composition enables precise 3D printing of objects with high refractive indices, reducing scattering and improving the formation of sharp edges and hollow bodies while minimizing ash or soot after sintering.
Implementation Method 1
The refractive index determines how much the path of light is bent, or refracted, when entering a material
Implementation Method 2
fillers having high refractive indexes cause light to bend and scatter when exposed to such materials
Implementation Method 3
both SLA and DLP printers employ light to polymerize the resin thereby securing the fillers in desired locations
Implementation Method 4
a high decomposition rate to reduce the prevalence of ash or soot being left behind after sintering
Data Source
AI summary
Disclosed are high refractive index monomers for ceramic/metal 3D printing applications. The compositions disclosed herein have a higher refractive index and thus better resolution and lower scattering of the light when employed in a composition to deposit ceramic or metallic particles. The disclosed compositions also include low refractive cross-linkers selected for their good thermal decomposition and reactivity to provide good cohesion during the 3D printing.