3D Printing Build Material with Isocyanurate Acrylate for High Stiffness
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Solution Overview
Problem
Existing 3D printing materials lack the necessary mechanical and thermal properties for high-stiffness parts, particularly in engineering applications, and often contain non-reactive wax components that can affect the printing process.
Innovation Solution
A build material comprising 10-30% oligomeric curable material, 50-75% diluent, and 3-15% reactive component, with the reactive component being isocyanurate (meth)acrylate, and optionally additives like photoinitiators, inhibitors, and stabilizing agents, which is free or substantially free of non-reactive wax, to achieve enhanced mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional build materials are used in 3D printing systems, then the printing process can be completed, but the finished parts lack sufficient mechanical strength and stiffness for engineering applications
Solution Approach 1:
The patent uses a composite build material system comprising multiple components: oligomeric curable material (10-30 wt%), reactive component (3-15 wt%, specifically isocyanurate (meth)acrylate), and diluent (50-75 wt%). This composite formulation achieves tensile strength greater than 45 MPa and tensile modulus greater than 2200 MPa, resolving the contradiction between achieving sufficient strength and maintaining reliable mechanical properties for engineering applications.
Solution Approach 2:
The patent modifies the chemical composition parameters of the build material by specifying precise weight percentage ranges for each component and eliminating non-reactive wax content to less than 5 wt% (preferably less than 1 wt% or 0.5 wt%). This parameter optimization enables the material to achieve both the required tensile strength (>45 MPa) and consistent mechanical reliability, particularly with heat deflection temperature between 45°C to 100°C.
2Ease of operation
If non-reactive wax components are added to build material, then the material flow properties improve, but the mechanical and thermal properties of finished parts deteriorate
Solution Approach 1:
The patent extracts and removes non-reactive wax components from the build material formulation, limiting their content to less than 5 wt% (preferably less than 1 wt% or 0.5 wt%). This extraction eliminates the harmful effect of waxes on mechanical strength while preserving adequate material flow properties through the use of reactive diluents (50-75 wt%) that provide both flowability and contribute to the cured mechanical properties.
Solution Approach 2:
The patent changes the compositional parameters by strictly limiting non-reactive wax content and replacing it with reactive components including oligomeric curable material (10-30 wt%) and reactive diluent (50-75 wt%). This parameter change enables the material to maintain ease of operation through proper viscosity control while achieving tensile strength greater than 45 MPa, resolving the contradiction between material flow and mechanical strength.
3Strength
If the build material formulation is optimized for high stiffness, then engineering applications become feasible, but the material composition complexity increases
Solution Approach 1:
The patent employs a composite material system with three main components in specific proportions: oligomeric curable material (10-30 wt%), reactive component (3-15 wt%, specifically isocyanurate (meth)acrylate), and diluent (50-75 wt%). This composite approach achieves high stiffness (tensile modulus greater than 2200 MPa) suitable for engineering applications while managing composition complexity through defined ranges and clear functional roles for each component.
Solution Approach 2:
The patent optimizes compositional parameters within specific ranges rather than using fixed ratios, allowing flexibility in formulation: oligomeric curable material (10-30 wt%), reactive component (3-15 wt%), diluent (50-75 wt%), with non-reactive wax less than 5 wt%. This parameter optimization achieves the target stiffness (tensile modulus >2200 MPa) while controlling complexity through standardized component categories and well-defined concentration ranges.
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 build material exhibits a tensile modulus greater than 2200 MPa, tensile strength greater than 45 MPa, and break elongation of 5-20%, along with a heat deflection temperature ranging from 45°C to 100°C, making it suitable for various engineering applications.
Implementation Method 1
a build material described herein comprises about 10 to 30 percent by weight of an oligomeric curable material; about 50 to 75 percent by weight of at least one diluent; and about 3 to 15 percent by weight of a reactive component... the reactive component of a build material described herein comprises an isocyanurate (meth)acrylate
Implementation Method 2
a build material described herein can further comprise one or more additives selected from the group consisting of photoinitiators, inhibitors, stabilizing agents, sensitizers, and combinations thereof
Implementation Method 3
In other instances, the build material is liquid at ambient temperatures... a build material described herein exhibits high stiffness, thereby providing finished parts that are useful in various engineering applications
Data Source
AI summary
In one aspect, build materials operable for use in 3 D printing systems are described herein. In some embodiments, a build material comprises about 10 to 30 percent by weight of an oligomeric curable material; about 50 to 75 percent by weight of at least one diluent; and about 3 to 15 percent by weight of a reactive component. Moreover, in some cases, the build material is free or substantially free of a non-reactive wax component.