3D Printing Low Viscosity Materials with Enclosure Moulds
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Solution Overview
Problem
Conventional 3D printing methods struggle with precision and material overspray when printing low viscosity materials, which are often non-printable due to rapid solidification requirements or incompatibility with biotechnological applications, especially where strong light energy cannot be used.
Innovation Solution
A 3D printing process involving multiple print passes with different materials, where a first material forms an enclosure or mould for a low viscosity material that initially lacks self-supporting strength, allowing it to be printed accurately without overspray, and a sacrificial material can be used for biocompatible constructs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If low viscosity materials are printed using conventional 3D printing methods, then printing speed and material versatility are improved, but material overspray over already printed lower structure layers occurs and manufacturing precision deteriorates
Solution Approach 1:
A support structure is printed first before depositing the low viscosity material. This preliminary action creates a mould area that confines the low viscosity material during printing, preventing overspray while maintaining high printing speed and accuracy.
Solution Approach 2:
The printing process is segmented into multiple passes: first printing a support structure, then printing the low viscosity material within the confined space. This segmentation allows each material to be optimized for its specific function without interfering with the other.
2Adaptability or versatility
If low viscosity materials are used to achieve material versatility, then ease of printing is improved, but the materials lack self-supporting strength and manufacturing precision deteriorates
Solution Approach 1:
A support structure acts as an intermediary element that provides the necessary mechanical strength and confinement for printing low viscosity materials. The support structure enables the low viscosity material to be printed with high precision even though the material itself lacks self-supporting strength.
3Productivity
If multiple inkjet nozzles are used for printing low viscosity curable materials, then printing capability is improved, but the process becomes unsuitable for biotechnological applications where strong light energy cannot be used
Solution Approach 1:
The patent replaces the stereolithographic light energy source (optical system) with a mechanical inkjet printing system that deposits materials layer by layer without requiring strong light energy for curing. This substitution makes the process suitable for biotechnological applications while maintaining printing capability.
Solution Approach 2:
The patent changes the fundamental printing parameter from light-based curing to material deposition. By using inkjet technology that relies on controlled material ejection rather than photopolymerization, the process becomes compatible with light-sensitive biotechnological materials.
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 high-precision 3D printing of low viscosity materials with reduced overspray and the ability to create complex structures suitable for biotechnological applications, such as tissue engineering and cancer research, by using self-assembling polymers and biocompatible sacrificial materials.
Implementation Method 1
The first material print pass(es) provides an enclosure or mould area, referred to in said previous related application as a 'template negative space/void mould' to be in-filled by the second subsequent print pass of low viscosity material
Implementation Method 2
3D printing of self-assembling polymeric materials such as self-assembling gels, by material deposition from a dispensing nozzle
Implementation Method 3
The second material can be a self-assembling polymer such as one or more of: collagen types 1 to 28, jellyfish collagen, nascent protein polypeptides
Data Source
AI summary
Disclosed herein is a process for 3D printing low viscosity material to produce a 3D printed article, the process comprising the steps of: a) providing software for moving a printing head relative to the article being printed; b) moving the print head relative to the article being printed according to the software, such that the article is printed in a layer by layer manner in multiple layers each having an article area; c) for at least some of the layers, printing a first material only to a first part of the article area, and printing a second material only to a second part of the article area different to the first area; and wherein, the first material is self-supporting to provide an enclosure for the second material which is a low viscosity, substantially non self-supporting, material when printed initially, which is preferably a self-assembling material forming a self-supporting article after maturing, so the first supporting material can then be removed if required.