Photocurable Resin Composition for Stereolithography
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current photocurable resin compositions used in stereolithography and 3D printing lack sufficient impact resistance, green strength, and thermal stability, which are essential for producing parts with mechanical properties comparable to materials like ABS and polycarbonate, and they often require post-curing processes to achieve full strength.
Innovation Solution
A photocurable resin composition comprising an epoxy resin, a block copolymer with a methyl methacrylate block as an impact modifier, a polymerization photoinitiator, a mono- or polyfunctional (meth)acrylate compound, and a polyol, which undergoes phase separation during curing to enhance mechanical properties without compromising flexibility or heat deflection temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional photocurable resin compositions are used in stereolithography, then the curing process can be completed, but the resulting parts lack sufficient impact resistance and green strength
Solution Approach 1:
The patent employs a composite resin system combining epoxy resin with (meth)acrylate monomers and oligomers, creating a dual-curing network that achieves both high impact resistance and balanced mechanical properties. The epoxy component provides toughness and adhesion, while the (meth)acrylate components contribute to crosslinking density and mechanical strength, resulting in a synergistic composite material that satisfies multiple performance requirements simultaneously.
Solution Approach 2:
The patent systematically adjusts the compositional parameters of the resin system, specifically controlling the ratios of epoxy resin to (meth)acrylate components, and optimizing the molecular weight and functionality of the oligomers. These parameter changes enable fine-tuning of the cured resin's mechanical properties, achieving the desired balance between impact resistance, green strength, and overall structural integrity without requiring post-curing processes.
2Strength
If traditional photocurable resin compositions are used, then the curing process can proceed, but the green strength is insufficient for easy handling during build
Solution Approach 1:
The resin composition is formulated to achieve adequate green strength during the in-build curing process itself, eliminating the need for subsequent post-curing operations. The dual-curing mechanism ensures that sufficient mechanical strength develops during the stereolithography build, allowing parts to be handled immediately after fabrication. This preliminary action approach integrates the strengthening function into the primary manufacturing process, saving time and simplifying the workflow.
3Strength
If conventional resin formulations are used, then the basic curing function is achieved, but the toughness is insufficient to match ABS and polycarbonate
Solution Approach 1:
The patent employs multi-functional (meth)acrylate oligomers that simultaneously serve as crosslinking agents, viscosity modifiers, and toughness enhancers. These oligomers contain multiple reactive groups that participate in the curing reaction while their molecular structure contributes to the final material's mechanical properties. This multi-functionality reduces the need for multiple separate additives, simplifying the overall formulation while achieving the desired toughness comparable to commercial thermoplastics like ABS and polycarbonate.
4Stability of the object's composition
If epoxy-acrylic resin mixtures are used for stereolithography, then clear photocurable composition is achieved, but impact resistance requires additional tougheners
Solution Approach 1:
The patent merges the epoxy resin system with the (meth)acrylate-based photopolymerizable components into a unified dual-curing formulation. This combination integrates the adhesion and toughness benefits of epoxy with the rapid photopolymerization and clarity of (meth)acrylate systems. The merged formulation achieves homogeneous mixing and consistent curing behavior, providing both the compositional stability needed for clear photocurable composition and the enhanced impact resistance that would otherwise require separate toughening agents.
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 achieves significant improvements in impact resistance, green flexural modulus, and tensile modulus, resulting in parts with balanced mechanical properties and improved handling during the build process, without the need for post-curing, and maintains thermal stability.
Implementation Method 1
a photoinitiator for polymerization
Implementation Method 2
which undergoes phase separation during curing to enhance mechanical properties
Data Source
AI summary
The present invention provides a curable composition comprising: (a) a resin composition being liquid at 23°C and comprising monomers or oligomersora mixture of monomers and oligomers polymerizable by a ring-opening reaction; (b) an impact modifier containingone or moreblock copolymers having at least one block composed of methyl methacrylate and (c) one or more polymerization initiators. The curable resin composition can be used for curablecoatings per seand in specific for stereolithographyand other applications such as three dimensional printing applications where a 3D object is formed.