Light-Curable Resin with Selective Solubility for 3D Printing
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Solution Overview
Problem
Three-dimensional printed parts often require difficult post-processing to remove supports due to the insolubility and toughness of the resin used, especially when the parts have intricate shapes or are made of resistant materials.
Innovation Solution
A polymerizable liquid composition for additive manufacturing is developed, incorporating a free radical photoinitiator, monomers/prepolymers with acid- or base-labile groups, and a photoacid or photobase generator, allowing for the creation of regions with different solubility and melting temperatures, enabling easier removal of supports by selective dissolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If covalently crosslinked thermoset materials or light-curable three-dimensional printing resins with multifunctional reactive groups are used, then the strength and structural integrity of the printed parts are improved, but the materials become insoluble and cannot be readily dissolved, making support removal difficult
Solution Approach 1:
The patent applies local quality by creating regions with different solubility characteristics within the same printed object. The resin composition includes functional groups that can be selectively activated or deactivated in different regions, allowing the main structural parts to remain insoluble and strong while support structures become soluble and easily removable through selective dissolution
Solution Approach 2:
The patent utilizes parameter changes by modifying the chemical structure of the resin through the inclusion of functional groups (such as acid-labile or base-labile groups) that can change their solubility properties under specific conditions. By controlling the activation of these functional groups in different regions, the patent enables selective solubility transformation without compromising the overall structural integrity of the printed part
2Strength
If tough resin materials resistant to cutting and sanding are used to produce three-dimensional parts, then the strength and durability of the parts are improved, but the difficulty of post-processing (cutting and sanding) increases significantly
Solution Approach 1:
The patent creates local quality differentiation by making support structures soluble while keeping the main part tough and insoluble. This allows the main structural components to maintain their toughness and resistance to mechanical processing, while supports can be easily removed through chemical dissolution rather than mechanical means
Solution Approach 2:
The patent replaces mechanical post-processing methods (cutting and sanding) with chemical dissolution methods. Instead of mechanically removing supports from tough resin parts, the patent enables chemical removal through selective dissolution of soluble support structures, significantly reducing post-processing difficulty
3Manufacturing precision
If traditional support structures are used in three-dimensional printing, then fine and delicate structures and overhangs can be printed, but a significant amount of post-printing effort is needed to remove supports by clipping or sawing and sanding
Solution Approach 1:
The patent applies local quality by differentiating the solubility properties of different regions in the printed object. Support structures are formulated with soluble functional groups while the main structure remains insoluble, enabling selective removal of supports through dissolution without affecting the integrity of the fine and delicate structures
Solution Approach 2:
The patent replaces mechanical support removal methods (clipping, sawing, sanding) with chemical dissolution methods. This substitution dramatically reduces the time and effort required for support removal while preserving the precision of fine structures that would be difficult to process mechanically
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 composition allows for the formation of three-dimensional objects with easily removable support structures, reducing the complexity of post-processing by creating acidic or basic regions that can be dissolved or melted, facilitating the production of complex shapes without the need for extensive cutting or sanding.
Implementation Method 1
monomers and/or prepolymers (e.g., reactive diluents) that are polymerizable by exposure to actinic radiation or light
Implementation Method 2
a photoacid generator, wherein said free radical photoinitiator and said photoacid generator are, or are selected to be, activated by light at different ranges of wavelengths or intensities
Implementation Method 3
monomers and/or prepolymers (e.g., reactive diluents) that are polymerizable by exposure to actinic radiation or light, optionally wherein some or all of said monomers and/or prepolymers comprise one or more acid-labile groups
Data Source
AI summary
Provided herein is a polymerizable liquid composition useful for additive manufacturing, which composition may include: (i) a free radical photoinitiator; (ii) monomers and/or prepolymers (e.g., reactive diluents) that are polymerizable by exposure to actinic radiation or light, optionally wherein some or all of said monomers and/or prepolymers comprise one or more acid-labile or base-labile groups; (iii) a crosslinker comprising one or more acid-labile or base-labile groups; and (iv) a photoacid generator or a photobase generator, wherein said free radical photoinitiator and said photoacid generator or photobase generator are, or are selected to be, activated by light at different ranges of wavelengths or intensities. Methods of forming a three-dimensional object with the composition, and articles so formed are also provided. Methods of removing a portion of the article by dissolving in a polar or non-polar solvent are further provided.