Latent Cure Resins for Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing materials, particularly polymeric (meth)acrylates, are limited by brittleness and inhomogeneity, restricting their application in functional prototyping and end-use scenarios due to high reactivity and cross-linking, which affects material properties and usability.
Innovation Solution
The development of latent cure resins comprising a first precursor component that cures with actinic radiation and a second precursor component that cures with moisture or gas, allowing for a two-step curing process to achieve enhanced mechanical properties and expanded material capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymeric (meth)acrylates are used for additive manufacturing, then the printing process proceeds quickly with high reactivity and accuracy, but the end material becomes brittle and inhomogeneous due to high cross-linking
Solution Approach 1:
The curing process is segmented into two distinct stages: first, actinic radiation cures the (meth)acrylate component to achieve rapid initial setting and layer adhesion; second, moisture or gas triggers curing of the isocyanate component to develop final mechanical properties. This segmentation allows each curing mechanism to contribute optimally without the drawbacks of complete cross-linking from the start.
Solution Approach 2:
The patent changes the curing parameters by introducing a dual-cure system where the first cure uses actinic radiation (light wavelength, rapid reaction) and the second cure uses moisture or gas (chemical reaction, slower development). This parameter change transforms the material from a single-state cross-linked network to a progressive curing system that evolves from rapid initial set to gradual strength development, reducing brittleness while maintaining productivity.
2Productivity
If polymeric (meth)acrylates are used for additive manufacturing, then high reactivity is achieved, but the resulting polymer is inhomogeneous and highly cross-linked, limiting material capabilities
Solution Approach 1:
The patent creates a composite curing system combining two different polymer chemistry pathways: (meth)acrylate photopolymerization and isocyanate moisture/gas-curing. This composite approach allows the first component to provide rapid initial structure formation while the second component contributes to homogeneous final properties through a different reaction mechanism, avoiding the inhomogeneity inherent in single-cure highly cross-linked systems.
3Manufacturing precision
If high cross-linking is achieved through radical photopolymerization, then printing accuracy improves, but the end material becomes brittle
Solution Approach 1:
The first curing action using actinic radiation performs the preliminary function of rapidly forming the green structure with adequate green strength for handling and layer adhesion. This preliminary cross-linking provides sufficient precision and structural integrity during printing, while the second moisture- or gas-triggered curing action subsequently develops the final mechanical properties including ductility and toughness, separating the precision function from the brittleness problem.
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
This approach enables the creation of materials with improved strength, toughness, and versatility, overcoming the limitations of single-cure resins by forming an interpenetrating polymer network, extending the range of accessible polymeric chemistries and material properties in additive manufacturing.
Implementation Method 1
the first precursor component is configured to cure when subjected to an effective amount of actinic radiation
Implementation Method 2
the second precursor component is configured to cure when subjected to moisture or gas
Data Source
AI summary
The present disclosure relates generally to curable resins, in particular latent cure resins, and related methods for use in an additive fabrication (e.g., 3-dimensional printing) device.