Micro-Composite Material for 3D Printing Edge Acuity
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Solution Overview
Problem
In 3D printing, the use of micronized particles in photocurable materials leads to light scattering, which deteriorates edge acuity and dimensional accuracy due to edge bleeding during the curing process.
Innovation Solution
Incorporating a small amount of dye with an absorption spectrum matched to the curing light wavelength into the micro-composite material to absorb scattered photons, maintaining mechanical properties while reducing edge bleeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If micronized particles are used in photocurable materials for 3D printing, then the material can be processed and cured, but light scattering occurs which deteriorates edge acuity and dimensional accuracy
Solution Approach 1:
A dye is introduced as an intermediary substance that absorbs scattered light photons, preventing them from causing edge bleeding. The dye acts as a mediator between the micronized particles and the curing light, capturing the scattered photons and converting their energy to prevent unwanted curing at edges.
Solution Approach 2:
The scattered light, which originally causes harmful edge bleeding, is converted into a beneficial effect by the dye that absorbs these photons. The harmful scattered photons are transformed into absorbed energy, preventing the unwanted curing effect at the edges of the printed structure.
2Productivity
If micronized particles are used in photocurable materials, then the material can be deposited and cured, but edge bleeding occurs during the curing process
Solution Approach 1:
The dye serves as a mediator that intercepts scattered photons during the curing process, preventing them from reaching the edges and causing bleeding. This intermediary substance allows the curing process to proceed efficiently while blocking the harmful light paths that would compromise dimensional accuracy.
Solution Approach 2:
The absorption spectrum of the dye is specifically matched to the wavelength of the curing light to maximize photon absorption. By changing the optical parameters of the material system, the dye efficiently captures scattered photons at the critical wavelength, preventing edge bleeding while maintaining curing efficiency.
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 solution achieves excellent edge acuity with minimal edge bleeding, allowing for precise dimensional accuracy and enabling the use of 3D printing in applications requiring high precision, such as dental applications.
Implementation Method 1
Incorporating a small amount of dye with an absorption spectrum matched to the curing light wavelength into the micro-composite material to absorb scattered photons
Data Source
AI summary
The present disclosure provides a micro-composite material used in the fabrication of three-dimensional objects, and associated methods and systems. In one example, a micro-composite material used in the fabrication of a three-dimensional object can comprise micronized polymeric particles; a photocurable curing agent; and a dye present in the micro-composite material in an amount at from 0.0001 wt % to 0.1 wt %, the dye having a λmax between 350 nm and 800 nm.