Inkjet 3D Printing Multi-Component Resins
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Solution Overview
Problem
The challenge in 3D inkjet printing is finding inks that remain liquid and stable within a printer, as many materials with desirable properties, such as resins, have limited 'pot life' and are prone to clogging or ruining the printer due to changes in rheological properties.
Innovation Solution
A system that mixes resin precursors just before use in an inkjet printer, using a metering and mixing system to maintain suitable viscosity and stability, along with a cleaning system to prevent clogging and extend the 'pot life' of the resin, including sensors for feedback control and a recirculation system to ensure fresh resin is always available.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resins with desirable properties (high toughness, heat deflection temperature, elongation at break) are used, then the mechanical properties of the printed object are improved, but the resin undergoes rapid curing and changes in rheological properties, causing clogging and printer failure
Solution Approach 1:
The resin system is segmented into separate precursor components that are stored independently and mixed only immediately before use. This segmentation prevents premature curing reactions while allowing the use of high-performance resin chemistries. The precursors remain stable in their separate states but react rapidly when combined, providing both reliability and mechanical property enhancement.
Solution Approach 2:
The precursors are prepared and pre-characterized in advance to ensure optimal mixing ratios and reaction characteristics. The system pre-establishes the correct formulation proportions and stores precursors under controlled conditions, enabling rapid mixing just before printing without requiring extensive on-site formulation work. This preliminary preparation ensures consistent results while maintaining printer reliability.
2Reliability
If conventional inkjet printing is used with stable inks, then the printer operates reliably without clogging, but the range of usable materials is limited to inks with specific viscosity and surface tension properties
Solution Approach 1:
A mixing system acts as an intermediary between the stable precursor components and the printhead. This intermediary device combines precursors in controlled ratios immediately before ejection, creating a usable resin mixture on-demand. The mixing system translates stable, versatile precursor formulations into jettable resin while maintaining printer reliability, thus expanding material adaptability without sacrificing operational stability.
Solution Approach 2:
The system dynamically changes the physical parameters of the resin by controlling the mixing ratio, temperature, and timing of precursor combination. By adjusting these parameters, the system can optimize resin viscosity and other flow properties for jetting while maintaining the chemical stability of the stored precursors. This parameter control enables a wide range of resin formulations to be used reliably in the inkjet printer.
3Duration of action of moving object
If resins with extended pot life are used, then the resin remains usable for longer periods in the printer, but the mechanical properties and performance of the cured resin are compromised
Solution Approach 1:
The resin system is divided into separate precursor components that do not react until mixed. This segmentation effectively extends the usable life of the precursor components indefinitely, as they remain stable in their separate stored states. Only upon mixing do they begin to react, providing full pot life extension without compromising the final cured resin properties, since the complete reaction occurs at the optimal moment for printing.
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 use of previously unusable resins like polyurethanes and silicones by maintaining their properties within a usable range, preventing clogging, and extending the 'pot life' of the resin, thus allowing for efficient and reliable 3D printing.
Implementation Method 1
The metering system includes a syringe pump, a diaphragm pump, a peristaltic pump, a piston pump, and a positive displacement pump
Implementation Method 2
The mixer thoroughly mixes these precursors and feeds the resulting resin to the printheads
Implementation Method 3
A cleaning system removes residual resin during or after printing
Implementation Method 4
The liquid ink is solidified using UV or visible-light radiation
Data Source
AI summary
An inkjet printer includes a mixer and a metering system that system provides appropriate amounts of the resin's precursors into the mixer. The mixer thoroughly mixes these precursors and feeds the resulting resin to the printheads. The inkjet printer may include a cleaning system that removes residual resin during or after printing.