Low-Temperature 3D Inkjet Resin Formulations With Fast Curing
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Solution Overview
Problem
Current 3D inkjet printing technologies require high working temperatures (typically 50-90°C) that are unsuitable for printing temperature-sensitive materials and limit applications to controlled environments, such as offices or homes.
Innovation Solution
Development of modeling material formulations with low viscosity (up to 50 cps at 35°C) and fast curing times (less than 20 seconds) that are compatible with 3D inkjet printing systems, allowing jetting without heating and suitable for temperature-sensitive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional photopolymerization resins are used in additive manufacturing, then high printing temperatures (above 50°C) are required to achieve adequate layer adhesion and material flow, but this causes patient discomfort and limits clinical applicability
Solution Approach 1:
The patent modifies the chemical composition parameters of the photopolymerization resin by incorporating specific monomers (ethylene glycol dimethacrylate, triethylene glycol dimethacrylate, pentaerythritol tetramethacrylate) and photoinitiators that enable polymerization at reduced temperatures. This parameter change in material formulation allows printing temperatures to be lowered from conventional >50°C to below 50°C while maintaining adequate layer adhesion and material flow properties.
Solution Approach 2:
The patent creates a composite photopolymerization resin system combining multiple monomers with different molecular weights and reactivities, along with specific photoinitiators. This composite material formulation synergistically enables low-temperature polymerization while maintaining the necessary rheological properties for additive manufacturing, resolving the contradiction between temperature reduction and printability.
2Strength
If high printing temperatures are used to ensure adequate layer adhesion, then material flow and bonding improve, but thermal degradation of the resin occurs and print precision deteriorates
Solution Approach 1:
The patent changes the chemical parameters of the resin formulation to include monomers with optimized viscosity and reactivity ratios, enabling strong layer adhesion at lower temperatures. This prevents thermal degradation while maintaining adequate bonding strength, thereby preserving print precision and avoiding the deterioration that occurs with conventional high-temperature printing.
3Productivity
If the resin viscosity is reduced to improve material flow at low temperatures, then printability improves, but the green strength of printed layers decreases
Solution Approach 1:
The patent formulates a composite resin system incorporating monomers of varying molecular weights and viscosities. The lower viscosity monomers (e.g., ethylene glycol dimethacrylate) provide adequate material flow for printability, while the higher viscosity monomers (e.g., pentaerythritol tetramethacrylate) contribute to crosslink density and green strength. This composite approach resolves the contradiction between flow and strength.
Solution Approach 2:
The patent creates local quality differentiation within the resin system by using monomers with distinct functional properties. Specific monomer regions provide flow characteristics while other regions provide strength characteristics, allowing the material to exhibit both low viscosity for printability and high green strength for structural integrity.
4Use of energy by moving object
If conventional photopolymerization resins are used, then high energy UV irradiation is required for complete polymerization, but this causes subsurface scattering and incomplete curing
Solution Approach 1:
The patent changes the photoinitiator system parameters by incorporating photoinitiators with absorption maxima in the blue light region (405-480 nm) rather than requiring high energy UV irradiation. This parameter change enables complete polymerization with lower energy irradiation, eliminating subsurface scattering issues while maintaining high polymerization efficiency and curing completeness.
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 production of 3D objects with properties similar to existing materials (e.g., Vero ™< and Tango ™< ) at lower temperatures, expanding application possibilities to non-controlled environments and facilitating the printing of biomolecules and other sensitive materials.
Implementation Method 1
The resin is a photopolymerization resin comprising a monomer and a photoinitiator
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
Modeling material formulation systems usable in additive manufacturing, 3D inkjet printing in particular, of three-dimensional objects, are provided. The formulations comprise two or more curable materials, such that an average molecular weight of the curable materials in each formulation is no more than 500 grams/mol, such that each formulation features a viscosity of no more than 50 centipoises at a temperature of 35 °C. Kits comprising the formulations or formulation systems and additive manufacturing processes utilizing same are also provided.