Inkjet Printing Metal Oxide Nanoparticle Sols for High Resolution 3D Articles
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Solution Overview
Problem
Current additive manufacturing techniques using inkjet printing struggle with achieving high resolution and variability in optical or mechanical properties over small areas or volumes due to limitations in inkjetting metal oxide nanoparticles with small particle sizes through nozzles of varying diameters.
Innovation Solution
The method involves inkjetting a sol through a nozzle with a diameter of 10 micrometers to 70 micrometers, using a sol comprising 5% to 40% metal oxide particles with an average size of 20 nanometers or less, a solvent, a surface modifying agent, and optionally a polymerizable component, to form droplets that can be solidified and repeated to create three-dimensional articles with specified geometries and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal oxide nanoparticles with small particle sizes are inkjetted through nozzles of varying diameters, then resolution and control over optical or mechanical properties are improved, but the process becomes difficult or impossible due to particle size limitations
Solution Approach 1:
The patent changes the physical-chemical parameters of the nanoparticle suspension (sol) including viscosity, surface tension, and particle size distribution to enable successful inkjet printing. Specifically, the sol is formulated with metal oxide particles of 1-20 nm diameter in a controlled concentration range (5-40 vol%), with adjusted viscosity (2-150 mPa·s) and surface tension properties to ensure proper flow through inkjet nozzles while maintaining high resolution printing capability
Solution Approach 2:
The patent introduces a sol formulation as an intermediary medium that contains the metal oxide nanoparticles. This sol acts as a carrier vehicle that enables the nanoparticles to be transported through the inkjet printing system. The sol includes surface-modified metal oxide particles dispersed in a liquid medium with specific rheological properties, serving as the bridge between the nanoparticle material and the inkjet printing process
2Manufacturing precision
If the nozzle diameter is reduced to achieve higher resolution, then manufacturing precision is improved, but the range of printable particle sizes becomes more restricted
Solution Approach 1:
The patent optimizes the particle size parameter to be 1-20 nm diameter, which is small enough to pass through fine inkjet nozzles (enabling high resolution) but large enough to maintain structural integrity and functional properties. The narrow particle size distribution within this range ensures compatibility with small nozzle diameters while providing versatility for different optical and mechanical property requirements
3Reliability
If the concentration of metal oxide particles is increased to achieve desired material properties, then the functional properties are improved, but the inkjet printing processability deteriorates due to increased viscosity
Solution Approach 1:
The patent identifies and controls multiple interrelated parameters: particle size (1-20 nm), concentration (5-40 vol%), viscosity (2-150 mPa·s), and surface tension. By optimizing these parameters together, the patent achieves a balance where sufficient metal oxide concentration provides the desired optical and mechanical properties while the controlled viscosity and surface tension maintain inkjet printability. The surface modification of particles also plays a role in preventing aggregation and maintaining flow properties
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
This approach enables the creation of high-resolution three-dimensional articles with controlled optical or mechanical properties by successfully inkjetting metal oxide nanoparticles, allowing for precise control over the composition and structure of the final product.
Implementation Method 1
inkjetting a sol through a nozzle having a diameter of 10 micrometers to 70 micrometers to form a plurality of droplets of printed sol
Implementation Method 2
a surface modifying agent
Data Source
AI summary
The present disclosure provides a method of making a three-dimensional article. The method includes a) inkjetting a sol through a nozzle having a diameter of 10 to 70 micrometers to form droplets of printed sol; b) solidifying the printed sol to form a portion of the three-dimensional article; and c) repeating steps a) and b) to form the three-dimensional article having a specified geometry. The sol includes i) 5 to 40 percent by volume of metal oxide particles, based on the total volume of the sol; ii) a solvent; iii) a surface modifying agent; and iv) optionally a polymerizable component. The metal oxide particles have an average particle size of 20 nanometers or less and of 1/100 to 1/10,000 of a diameter of the nozzle. The method enables high resolution additive manufacturing of an object having differences in one or more optical or mechanical property over a small area or volume of the object.