Model Material Composition for High-Speed 3D Printing
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Solution Overview
Problem
Conventional resin compositions for model materials in material jetting optical shaping methods face challenges in achieving high-speed shaping with high accuracy due to issues like shape loss, wet-spreading, and insufficient adhesion, leading to sagging and inaccuracies in layered structures.
Innovation Solution
A model material composition incorporating a polymerizable compound, a photopolymerization initiator, and a siloxane compound with a specific molecular weight range and polymerizable group, which enhances surface distribution and adhesion, allowing for precise lamination and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the material jetting optical shaping method is used to produce three-dimensionally shaped articles, then the shaping speed can be increased, but the shaping accuracy deteriorates due to shape loss, wet-spreading, and insufficient adhesion of overlaid compositions
Solution Approach 1:
The invention changes the chemical composition parameters of the resin composition by incorporating specific compounds (siloxane compound with one polymerizable group per molecule, polymerizable compound with two or more polymerizable groups per molecule, and compound with hydrolyzable group) in defined amounts. This modifies the material's surface tension, viscosity, and adhesion properties to enable high-speed shaping while maintaining high accuracy by preventing shape loss and wet-spreading.
Solution Approach 2:
The invention uses a composite resin composition combining multiple components: siloxane compound (0.001-5% by mass), polymerizable compound (5-50% by mass), compound with hydrolyzable group (5-50% by mass), and other additives. This composite formulation creates material with balanced properties for both rapid curing and strong layer adhesion, resolving the contradiction between speed and accuracy.
2Productivity
If the lamination cycle is repeated to form layered structures, then the three-dimensional shape can be built up, but sags occur due to interdiffusion and slipping out of overlaid composition
Solution Approach 1:
The invention performs preliminary action by incorporating the siloxane compound and polymerizable compound into the resin composition before ejection. These compounds are pre-positioned in the material to immediately form strong adhesion bonds upon landing on the previous layer, preventing slipping and sagging before they can occur during the lamination process.
Solution Approach 2:
The siloxane compound acts as an intermediary substance that mediates between the overlaid composition and the previous cured layer. It forms a strong interfacial bond through its polymerizable groups reacting with the previous layer, preventing interdiffusion and slipping while allowing efficient lamination cycles.
3Ease of manufacture
If conventional resin compositions are used, then the basic shaping function is achieved, but the mechanical properties and surface quality deteriorate due to insufficient adhesion and wet-spreading
Solution Approach 1:
The invention modifies the chemical parameters of the resin composition by adding specific compounds in optimized amounts. The siloxane compound (0.001-5% by mass) and polymerizable compound (5-50% by mass) change the material's molecular structure to improve mechanical strength and surface quality while maintaining ease of manufacture through standard material jetting processes.
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 enables high shaping accuracy and excellent mechanical properties even at high speeds by ensuring strong binding between layers and preventing sagging, thus overcoming the limitations of conventional resin compositions.
Implementation Method 1
a method for producing a three-dimensionally shaped article by irradiating a photocurable resin composition with light such as ultraviolet ray to form cured layers having a desired shape continuously
Implementation Method 2
when the model material composition drips at a drop volume of 1.8 ± 0.1 μL and lands on a cured article of the model material composition, a contact angle of a droplet of the model material composition against the cured article as measured 0.3 seconds after the landing is 40° or more
Data Source
Figure 1~2
AI summary
The present invention relates to a model material composition for shaping a model material by a material jetting optical shaping method, comprising a polymerizable compound, a photopolymerization initiator and a siloxane compound having one polymerizable group per molecule, the siloxane compound having a number average molecular weight of 300 to 10,000.