Printable Object Production with In-Situ Curing in Hydrogel Support

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Solution Overview

Problem

Existing 3D printing techniques face challenges in producing complex, biocompatible objects with good layer-to-layer adhesion and oxygen inhibition, especially when using hydrogels as supporting materials, which can contaminate surfaces and reduce dimensional accuracy.

Innovation Solution

A method involving a robocasting system with a movable printing element that injects printing material into a supporting material containing a free radical polymerization initiator, activated by light or microwaves, to ensure instant curing and adhesion without polymerizing the support material, using protective gases to inhibit oxygen and enhance polymerization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hydrogels are used as supporting materials in 3D printing, then biocompatibility is improved, but surface contamination and reduced dimensional accuracy occur

Engineering Contradiction:

ImprovebiocompatibilityVSAvoiddimensional accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

A release layer is introduced as an intermediary between the hydrogel supporting material and the printed object. This release layer prevents direct contact and adhesion between the hydrogel and the printed object surface, eliminating surface contamination while maintaining the biocompatibility benefits of hydrogels. The release layer acts as a temporary mediator that is removed after printing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If printing material is injected into supporting material, then layer-to-layer adhesion is improved, but oxygen inhibition of polymerization occurs

Engineering Contradiction:

Improvelayer adhesionVSAvoidpolymerization completeness

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The supporting material is designed to provide an oxygen-inert environment for the printing material. By formulating the supporting material with specific composition and structure, oxygen access to the printing material interface is restricted, preventing oxygen inhibition of polymerization while maintaining good layer adhesion through the injection process.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Productivity

If initiator is added to supporting material to accelerate curing, then curing speed is improved, but premature polymerization of supporting material may occur

Engineering Contradiction:

Improvecuring speedVSAvoidsupporting material stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The initiator is distributed locally within the supporting material at controlled concentrations, rather than uniformly throughout. This localized distribution allows the initiator to be present where needed to accelerate curing of the printing material, while the overall concentration remains low enough to prevent premature polymerization of the supporting material itself.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The chemical parameters of the supporting material are optimized to balance initiator activity with material stability. By adjusting initiator concentration, type, and activation conditions, the system achieves rapid curing of the printing material while maintaining the stability of the supporting material during the printing process.

Inventive Principle:

Principle #35Parameter changes

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 enables high-precision, biocompatible objects with improved layer adhesion and dimensional accuracy, allowing for the incorporation of additives like cells and compounds, suitable for tissue engineering scaffolds and dental constructs.

Implementation Method 1

activation on the supporting material with curing the injected printing material in the steps of the printing process using at least one light emitting source providing light that causes polymerization of the printing material and activation of the initiator in the supporting material

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

protective gas for ensuring polymerization of the of the printing material to occur with formation of the oxygen inhibited surface layer to the printing object

Methodology Applied

Scientific EffectOxygen inhibition:

Data Source

PatentUS12384100B2Method and system for producing a printable object

Publication Date: 2025.08.12 RAYO 3D BIOTECH OY

AI summary

Disclosed is a method for producing a printable object, the method comprising: injecting printing material using a printing element having a printing tip that is movable, into supporting material, wherein the supporting material comprises initiator that is free radical polymerization initiator compatible to enhance curing of the printing material while not causing polymerization of the supporting material, and curing the injected printing material using at least one light emitting source providing light that causes polymerization of the printing material, wherein the curing is performed simultaneously with the injecting of the printing material.