Ionic Polymer Support Material for 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing metal parts via investment casting face challenges in creating disposable foundry patterns that can be easily removed from refractory materials without damaging the mold, and 3D printing struggles with separating support materials from the printed article efficiently.
Innovation Solution
A curable composition comprising polymerizable ionic species that can be cured to form a thermoplastic material with ionic crosslinks, allowing for easy fragmentation in a protic liquid medium, such as water, and can be used as a support material in 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If (meth)acrylate-functionalized polyethers are used to create disposable foundry patterns, then the patterns can be photocured to provide structural integrity, but the patterns become swellable in water and very difficult to remove from refractory material without damaging the mold
Solution Approach 1:
The patent changes the chemical parameters of the photocurable composition by using (meth)acrylate monomers without polyether functional groups, eliminating the water-swelling property while maintaining photocurable structural integrity. This parameter change resolves the contradiction by allowing easy water-based removal without mold damage.
Solution Approach 2:
The patent employs disposable foundry patterns made from photocurable compositions that are designed to be easily removed after serving their temporary purpose. The patterns are intentionally made water-soluble or water-dispersible so they can be cleanly removed from the refractory mold using water, eliminating the need for complex removal processes.
2Strength
If support material is used in 3D printing to support layers during construction, then adequate support is provided, but the support material becomes intimately associated with the article and difficult to separate
Solution Approach 1:
The patent changes the chemical parameters of the support material by using (meth)acrylate monomers that form water-soluble or water-dispersible polymers upon photocuring. This allows the support material to maintain structural integrity during printing while enabling easy separation from the finished article through water rinsing.
Solution Approach 2:
The patent uses water as an intermediary substance to separate the support material from the finished 3D printed article. The support material is designed to be water-soluble or water-dispersible, allowing water to act as a mediator that selectively removes the support material without affecting the final product.
3Ease of operation
If traditional methods are used to remove support material or foundry patterns, then removal can be achieved, but harsh solvents or high-temperature burn-out processes are required
Solution Approach 1:
The patent changes the thermal and chemical parameters of the support material and foundry pattern composition by using (meth)acrylate monomers that form water-soluble or water-dispersible polymers. This eliminates the need for harsh solvents or high-temperature burn-out processes, allowing removal at ambient or mild temperatures using water.
Solution Approach 2:
The patent converts the potential harm of water exposure (which could damage traditional support materials) into a benefit by designing support materials and foundry patterns that are specifically engineered to be water-soluble or water-dispersible. This allows water, typically a benign substance, to become an effective removal agent that eliminates the need for harsh chemicals or high temperatures.
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 efficient removal of support materials from 3D printed articles and disposable foundry patterns without damaging the mold, facilitating high-quality finished products and reducing the need for harsh solvents or high-temperature burn-out processes.
Implementation Method 1
A+B− wherein A+ is a cationic species comprising a cationic functional group and a first polymerizable, ethylenically unsaturated functional group; and B− is an anionic species comprising an anionic functional group and a second polymerizable, ethylenically unsaturated functional group
Implementation Method 2
the cured composition which displays thermoplastic behavior in the absence of a protic liquid medium, is fragmentable in a protic liquid medium
Data Source
AI summary
Curable compositions contain at least one polymerizable ionic species and, when cured (for example, by photocuring), provide cured compositions which are thermoplastic and yet fragmentable by a protic liquid medium such as water. The polymerizable ionic species corresponds to Formula (I) A+B− wherein A+ is a cationic species having a cationic functional group and a first polymerizable, ethylenically unsaturated functional group; and B″ is an anionic species having an anionic functional group and a second polymerizable, ethylenically unsaturated functional group which is the same as or different from the first polymerizable, ethylenically unsaturated functional group. The curable compositions are useful for forming sacrificial or temporary articles, for example by three-dimensional printing methods.