Low-Temperature Support Material Formulation for Water-Removable 3D Printing
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Solution Overview
Problem
Current 3D printing support materials are not suitable for low-temperature applications, such as office or home environments, due to increased viscosity at lower temperatures, requiring heating and using hazardous solvents, and are labor-intensive to remove, posing safety and environmental concerns.
Innovation Solution
A support material formulation with a viscosity of no more than 50 cPs at 35°C, comprising a hydrophilic curable material and a non-curable material, which is dissolvable or swellable in an aqueous solution, allowing for 3D inkjet printing without heating and safe, rapid removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If support materials are used in 3D printing at low temperatures, then the printing process can be performed in office or home environments without specialized equipment, but the viscosity of the support material increases making it unsuitable for inkjet printing
Solution Approach 1:
The support material formulation uses hydrophilic curable materials with specific molecular structures that maintain low viscosity at room temperature (35°C). The composition includes hydrophilic monomers and oligomers that do not require thermal energy to maintain jettable viscosity, fundamentally changing the temperature-viscosity relationship of the material.
Solution Approach 2:
The support material is formulated as a composite system combining hydrophilic curable materials with specific additives and modifiers. This composite formulation achieves the dual property of being jettable at low temperatures while maintaining structural integrity after curing, resolving the contradiction between temperature and jetting precision.
2Strength
If conventional support materials are used, then they can provide adequate support during printing, but they require hazardous solvents and labor-intensive removal processes
Solution Approach 1:
The support material's chemical composition is changed to be water-soluble through the use of hydrophilic curable materials. This parameter change in solubility allows the support to be removed by simple water washing instead of requiring hazardous solvents or labor-intensive mechanical removal, while maintaining adequate support strength during printing.
Solution Approach 2:
The support material is designed as a temporary, disposable component that can be easily removed after serving its purpose. The water-soluble formulation makes the support removable like a temporary structure, eliminating the need for complex removal processes while providing sufficient support during the printing process.
3Manufacturing precision
If heating is applied to reduce viscosity for jetting, then the material can be dispensed properly, but it increases energy consumption and complicates the printing system
Solution Approach 1:
The material's viscosity-temperature relationship is fundamentally changed by using hydrophilic curable materials that maintain low viscosity at room temperature. This eliminates the need for thermal energy input to achieve jettable consistency, reducing energy consumption while maintaining jetting precision through compositional rather than thermal control.
4Temperature
If hydrophilic curable materials are used to enable low-temperature jetting, then printing can be performed at 35°C with viscosity ≤50 cPs, but the material must be dissolvable or swellable in aqueous solutions
Solution Approach 1:
The support material is designed with dual functionality: it is stable and structurally sound during the printing process to provide adequate support, but is pre-formulated to be water-soluble or swellable for easy removal. The hydrophilic curable materials maintain compositional stability at printing temperatures while inherently possessing water solubility, resolving the contradiction between stability and removability.
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 3D printing at low temperatures without damaging print heads, facilitating safe and efficient removal of support materials, suitable for office environments and bioprinting applications.
Implementation Method 1
a swelling capacity of said hardened material for said at least one non-curable material or for a mixture of said at least one non-curable material and said water, if present, is of at least 70%
Implementation Method 2
The curable material is a UV-curable material, the formulation further comprising a photoinitiator
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
Formulations usable as support material in additive manufacturing such as 3D inkjet printing and which feature a viscosity of no more than 50cPs at 35°C, are provided. The formulations are composed of at least one hydrophilic curable material which provides, when hardened, a material that is dissolvable or swellable in an aqueous solution; and at least one non- curable material that is capable of being swelled by said hardened material formed of said at least one curable material. Additive manufacturing processes utilizing these formulations and objects obtained thereby are also provided.