Multiblock Copolymer Sacrificial Support for 3D Printing
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Solution Overview
Problem
Existing 3D printing techniques require support materials with specific thermomechanical properties and solubility characteristics, particularly for high-temperature polymers like PEEK and PEI, where the choice of sacrificial support polymers is limited and often difficult to store due to water solubility issues.
Innovation Solution
The use of multi-block copolymers as sacrificial materials in 3D printing, which exhibit rapid solubilization in various solvents and suitable thermomechanical properties, allowing them to support the printing of high-temperature polymers without the need for Tg matching with the polymer to be printed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If water-soluble or water-dispersible compositions and filaments are used as sacrificial materials, then rapid solubilization and dispersibility in water are achieved, but preservation during storage becomes difficult due to ambient humidity causing granules to cake or filaments to stick to spools
Solution Approach 1:
The patent uses multi-block copolymers comprising hydrophilic blocks (for water solubility) and hydrophobic blocks (for structural integrity and reduced humidity sensitivity). This composite structure at the molecular level allows the material to simultaneously achieve rapid water solubilization while maintaining storage stability by reducing unwanted interactions with ambient humidity.
Solution Approach 2:
The patent modifies the chemical composition parameters of the sacrificial material by using multi-block copolymers with specific block ratios and molecular weights. These parameter changes enable the material to have both rapid solubilization kinetics and improved storage stability by controlling the balance between hydrophilic and hydrophobic segments.
2Adaptability or versatility
If traditional support materials are used for high-temperature polymers (Tg 140-200°C), then the support material must have a glass transition temperature close to the polymer being printed, but this limits the choice of sacrificial support polymers and makes development difficult
Solution Approach 1:
The patent segments the support material into multiple functional blocks within the copolymer structure. Each block serves a specific function: hydrophilic blocks provide solubility control while hydrophobic blocks provide mechanical strength. This segmentation allows independent optimization of each block's properties, enabling the support material to work with a wide range of high-temperature polymers without requiring Tg matching.
Solution Approach 2:
The multi-block copolymer structure provides universal compatibility with various high-temperature polymers (PEEK, PEKK, PEI, PAI, PSU, PPS) by decoupling the support material's Tg from the printed polymer's Tg. The copolymer achieves this through its multi-functional design where different blocks independently contribute to mechanical properties, solubility, and thermal stability, making it a universal support material.
3Reliability
If multiple copolymers are used to adjust solubility and mechanical properties, then the desired properties are achieved, but the development process becomes more difficult
Solution Approach 1:
The patent merges multiple copolymer formulations into a single multi-block copolymer structure. Instead of using several different copolymers mixed together, all the desired functions (solubility control, mechanical strength, thermal stability) are integrated into one copolymer with multiple blocks, each contributing specific properties. This simplifies the development process while maintaining reliable mechanical properties.
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
This approach provides new possibilities for printing complex parts with high-temperature polymers, offering improved mechanical properties and solubility characteristics, while simplifying the development of support materials by decoupling Tg requirements.
Implementation Method 1
Such materials exhibit rapid solubilization or dispersibility in a variety of solvents while combining the ideal thermomechanical properties
Implementation Method 2
Fused Filament Deposition Modeling is a technique that involves melting a filament through an extrusion nozzle
Implementation Method 3
This wire is deposited in line and is bonded by re-melting to what was previously deposited
Data Source
Figure 1
AI summary
The present invention relates to the use of multiblock copolymer compositions as sacrificial materials of 3D fused deposition modeling.