Ion Cross-Linked Curable Liquid for High-Strength 3D Printing
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Solution Overview
Problem
Existing active energy ray curable liquids used in stereolithography and material jetting methods often result in fabrication objects with poor strength and inferior tensile properties, such as chipping when used as gears or failing to replicate strong, textured structures like organs accurately.
Innovation Solution
The use of an active energy ray curable liquid formulation containing an unsaturated acid monomer and a metal salt, which can form an ion cross-linked structure, enhancing the breaking stress and elongation ratio of fabricated objects, and optionally including a polymerizable monomer and solvent for improved stability and application in resin or gel fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional active energy ray curable liquids are used in stereolithography and material jetting methods, then the fabrication process can be completed, but the resulting objects exhibit poor strength and inferior tensile properties leading to chipping and structural failure
Solution Approach 1:
The patent employs a composite material system consisting of unsaturated acid monomers (providing polymerizable backbone), metal salts (providing crosslinking nodes), and optionally polymerizable monomers and solvents. This composite formulation creates a dual-network structure where metal ions coordinate with carboxylate groups to form ion crosslinks alongside covalent polymer networks, achieving superior mechanical strength and tensile properties that prevent chipping and structural failure in fabricated objects
Solution Approach 2:
The patent systematically varies compositional parameters including the type and ratio of unsaturated acid monomers, metal salt concentrations, and optional polymerizable monomer content to optimize the ion crosslinking density and network structure. By adjusting these parameters, the formulation achieves enhanced breaking stress and elongation ratio while maintaining printability and cure characteristics
2Manufacturing precision
If existing curable liquid formulations are used, then fabrication objects can be produced, but they fail to accurately replicate complex textures and strong structures such as organs
Solution Approach 1:
The composite formulation with ion crosslinked metal salt networks provides the mechanical strength and structural fidelity necessary to accurately replicate complex biological textures and strong structures. The coordinated metal-carboxylate crosslinks create a rigid yet flexible network that maintains dimensional accuracy and surface detail during the curing process, enabling faithful reproduction of organ-like structures with appropriate mechanical properties
Solution Approach 2:
The formulation enables differential property distribution within the fabricated object by controlling the local concentration and coordination chemistry of metal salts with unsaturated acid monomers. This allows regions of varying crosslink density and mechanical properties within the same object, facilitating accurate replication of complex textures and structures with spatially varying requirements for strength and flexibility
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 formulation achieves strong and durable fabrication objects with improved tensile strength and elongation ratio, preventing chipping in mechanical applications and accurately replicating complex textures, such as those found in organ models.
Implementation Method 1
The active energy ray curable liquid contains an unsaturated acid monomer and a metal salt, which form an ion cross-linked structure
Implementation Method 2
a photocurable liquid resin is irradiated layer by layer with laser beams or ultraviolet rays to fabricate a three-dimensional fabrication object
Data Source
AI summary
An active energy ray curable liquid contains an unsaturated acid monomer and a metal salt.