3D Printing Material System for Thick Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The fast curing mechanism of UV-initiated (meth)acrylate polymerization in 3D printing leads to excessive distortion and curling of printed parts, especially for thicknesses greater than 1 mm, due to instantaneous shrinkage, making it difficult to produce stable and strong articles without infiltration.
Innovation Solution
A 3D printing method using a particulate material system with a transition metal catalyst and a fluid binder containing a (meth)acrylate monomer, allyl ether functional monomer/oligomer, and organic hydroperoxide or photoinitiator, which slows down the curing rate, reducing distortion and eliminating the need for infiltration, while maintaining high strength comparable to infiltrated articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If UV initiation of (meth)acrylate polymerization is used for fast curing, then the forming process speed is improved, but excessive distortion and curling occur in printed parts
Solution Approach 1:
The patent changes the curing mechanism from UV photopolymerization to thermal curing using an organic peroxide initiator. This parameter change in the curing method allows the binder to cure slowly at elevated temperatures (e.g., 60-100°C) without the instantaneous shrinkage and distortion caused by rapid UV curing, thereby maintaining dimensional accuracy while still achieving complete curing.
Solution Approach 2:
The patent introduces an organic peroxide initiator as an intermediary substance that enables controlled thermal curing of the (meth)acrylate binder. The peroxide decomposes at elevated temperatures to generate free radicals that initiate polymerization, serving as a mediator between heat and the polymerization reaction, allowing controlled curing without direct UV light exposure.
2Speed
If UV initiation of (meth)acrylate polymerization is used, then curing speed is improved, but curling of printed parts occurs making thickness greater than 1 mm difficult to produce
Solution Approach 1:
The patent changes the curing parameters from room temperature UV curing to elevated temperature thermal curing. By heating the printed part to 60-100°C and using an organic peroxide initiator, the curing process proceeds at a controlled rate that prevents curling, enabling successful printing of parts with thickness greater than 1 mm.
Solution Approach 2:
The patent employs periodic or staged heating to achieve controlled curing. The thermal curing process can be applied in stages or with controlled temperature profiles, allowing the binder to cure progressively without causing immediate distortion, thereby enabling printability of thick parts.
3Loss of time
If fast UV curing is used, then process time is reduced, but infiltration step becomes necessary to achieve sufficient strength
Solution Approach 1:
The patent merges the binder curing process with the part formation process itself. By using thermal curing with organic peroxide initiator, the binder cures completely during the printing process without requiring a separate infiltration step, thereby reducing process complexity while maintaining strength.
Solution Approach 2:
The patent changes the curing mechanism to eliminate the need for infiltration. By using thermal curing with peroxide initiator instead of UV curing, the binder achieves complete polymerization and sufficient strength directly during printing, eliminating the need for additional infiltration processing steps.
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 method achieves strong and stable 3D printed parts without infiltration, with flexural strengths up to 20 MPa, allowing for the production of articles thicker than 1 mm without curling or distortion, and enables a stable two-component product with controlled curing.
Implementation Method 1
The fast curing mechanism of UV initiation of (meth)acrylate polymerization
Implementation Method 2
a transition metal catalyst and a fluid binder containing a (meth)acrylate monomer, allyl ether functional monomer/oligomer, and organic hydroperoxide or photoinitiator
Implementation Method 3
The binder infiltrates into gaps in the powder material and hardens to bond the powder material into a solidified layer
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A materials system is provided to enable the formation of articles by 3D printing. The materials system includes a substantially dry particulate material that includes an insoluble filler, a soluble filler, and a transition metal catalyst. The materials system further comprises a fluid binder including a (meth)acrylate monomer, an allyl ether functional monomer and/or oligomer, and a free-radical photoinitiator.