Ink-Jet 3D Printing Resin Solubility Parameter Control
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Solution Overview
Problem
In ink-jet three-dimensional printing, existing methods face challenges such as the need for dedicated dark rooms, high equipment costs, deformation of photofabrication models due to swelling, and difficulties in removing supporting materials, especially for complex shapes, where the modeling and supporting materials intermix and are difficult to separate without deforming.
Innovation Solution
A two-pack photocurable resin composition is developed, comprising a modeling material with a weighted average solubility parameter (SP value) of 9.0 to 10.3 and a supporting material containing a water-soluble monofunctional ethylenically unsaturated monomer, an alkylene oxide adduct, and a photopolymerization initiator, which allows for minimal swelling deformation, easy removal of the supporting material, and excellent mechanical properties of the photofabrication model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modeling material and supporting material are used in combination for ink-jet photofabrication, then complex shapes can be fabricated, but the photofabrication model deforms due to swelling when removing the supporting material
Solution Approach 1:
The patent applies parameter changes by carefully selecting and controlling the solubility parameters (SP values) of the modeling material and supporting material to be different from each other. The modeling material has an SP value of 9.0 to 10.3, while the supporting material has an SP value outside this range, ensuring that the supporting material can be removed by washing without causing the modeling material to swell or deform. This parameter differentiation resolves the contradiction by enabling complex shape fabrication while maintaining dimensional accuracy.
2Ease of manufacture
If the supporting material is removed by washing with water, then the supporting material can be eliminated, but the photofabrication model deforms due to swelling
Solution Approach 1:
The patent uses parameter changes by selecting materials with specific solubility parameters that create a clear distinction between the modeling material and supporting material. The modeling material (SP value 9.0-10.3) remains insoluble in water while the supporting material (SP value outside this range) is water-soluble, allowing easy removal without causing swelling deformation of the final model.
3Manufacturing precision
If conventional laser beam or ultraviolet ray photofabrication is used, then photofabrication models can be prepared, but dedicated dark rooms and expensive equipment are required
Solution Approach 1:
The patent replaces the conventional laser beam or ultraviolet ray photofabrication system with an ink-jet printing system. Instead of using complex optical systems requiring dark rooms and expensive equipment, the invention uses ink-jet nozzles to deposit liquid photocurable resin that is then cured with light. This substitution maintains the capability to prepare photofabrication models while dramatically reducing facility requirements and equipment costs.
4Ease of operation
If the modeling material and supporting material have similar properties, then they can be easily processed, but they intermix and become difficult to separate
Solution Approach 1:
The patent applies parameter changes by ensuring that the modeling material and supporting material have different solubility parameters. The modeling material has an SP value of 9.0 to 10.3, while the supporting material has an SP value outside this range. This parameter differentiation prevents intermixing and enables easy separation through water washing, as the supporting material dissolves while the modeling material remains intact.
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 solution results in minimal swelling deformation, easy removal of the supporting material, and enhanced working accuracy and mechanical properties of the photofabrication model, improving productivity and reducing costs associated with equipment and facilities.
Implementation Method 1
irradiating a liquid photocurable resin with light such as a laser beam or ultraviolet rays to cure the resin
Data Source
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AI summary
The present invention aims to provide a supporting material for supporting the shape of a photofabrication model on photofabrication in ink-jet three dimensional printing method in which the photocured product is excellent in solubility in water and is easy to remove after photofabrication, and the like. A modeling material for forming a photofabrication model in ink-jet three dimensional printing method containing a curable resin component with a weighted average of SP value of 9.0 to 10.3; and a supporting material for supporting the shape of a photofabrication model on photofabrication in ink-jet three dimensional printing method containing a water-soluble monofunctional ethylenically unsaturated monomer (F), polyoxypropylene glycol with a number average molecular weight of 100 to 5,000 and/or water (G), and a photopolymerization initiator (D).