3D Printing Polymerizable Liquid Composite Resin
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Solution Overview
Problem
Existing 3D printing materials, particularly UV-curable acrylate formulations, often result in parts with high resolution but lack desirable mechanical properties, leading to premature failure due to degradative pathways.
Innovation Solution
A polymerizable liquid comprising an acrylate component, a composite resin with polymeric particles dispersed in a curable carrier, and a photoinitiator, which is irradiated to form a polymeric composite with improved mechanical properties through a layer-by-layer process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV curable acrylate formulations are used for 3D printing, then high resolution is achieved, but mechanical properties deteriorate and parts become prone to fracture
Solution Approach 1:
The patent applies composite materials by combining acrylate monomers/oligomers with polymeric particles dispersed in a curable carrier. This creates a composite resin system that integrates the high-resolution curing capability of acrylates with the mechanical reinforcement provided by the polymeric particles, thereby achieving both high resolution and improved mechanical properties in the printed parts.
Solution Approach 2:
The patent changes the chemical composition parameters of the build material by incorporating specific ratios of acrylate components, polymeric particles, and photoinitiators. By adjusting these compositional parameters, the formulation achieves optimal balance between resolution (through UV curability) and mechanical strength (through composite structure and particle reinforcement).
2Manufacturing precision
If UV curable acrylate formulations are used for 3D printing, then high resolution is achieved, but reliability deteriorates due to degradative pathways
Solution Approach 1:
The composite resin system combines acrylate-based curable materials with polymeric particles that provide enhanced stability and resistance to degradation. This composite structure creates a more reliable printed part by integrating materials with complementary properties: the acrylate provides curability and resolution while the polymeric particles contribute to long-term stability and resistance against degradative pathways.
3Strength
If composite resin with polymeric particles is added to improve mechanical properties, then strength is improved, but device complexity increases
Solution Approach 1:
The patent manages complexity by optimizing the compositional parameters of the composite resin. Specific ratios of acrylate monomers, oligomers, polymeric particles, and photoinitiators are selected to achieve the desired mechanical properties while maintaining practical manufacturability. The formulation complexity is balanced against performance gains through careful parameter selection and control.
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 high-resolution 3D printed articles with enhanced mechanical properties, including impact resistance, tensile strength, and elongation at break, effectively addressing the premature failure issues of previous materials.
Implementation Method 1
The polymerizable liquid is irradiated with light to form the article, the article comprising a polymeric composite including a polymeric matrix comprising an acrylate phase and cured carrier phase
Implementation Method 2
a composite resin comprising a curable carrier and polymeric particles dispersed in the curable carrier
Data Source
AI summary
Polymerizable liquids are described herein which, in some embodiments, can produce 3D printed articles of high resolution and desirable mechanical properties. In one aspect, a polymerizable liquid comprises an acrylate component, and a composite resin comprising a curable carrier and polymeric particles dispersed in the curable carrier. The polymerizable liquid also comprises a photoinitiator component.