Reactive Particulate Materials for Additive Manufacturing
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Solution Overview
Problem
Conventional additive manufacturing techniques are slow and produce parts with limited mechanical properties, making them unsuitable for real-world applications beyond prototyping, and there is a need for sustainable chemistry approaches to enhance the production of three-dimensional objects.
Innovation Solution
A method of producing reactive particulate materials by recycling preformed articles or directly forming them using a single-cure resin comprising reactive blocked polyurethane or polyurea prepolymers, with optional reactive diluents and photo-initiators, through light polymerization and subsequent comminution, which can be used in additive manufacturing processes and recycled to create objects with improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional additive manufacturing techniques are used, then parts can be produced, but the production speed is slow and mechanical properties are limited
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the resin system. It uses a dual-cure mechanism combining photopolymerization (light-induced) and moisture cure (hydrolysis), allowing the material to achieve different property states at different stages. This enables rapid initial production followed by continued strength development, resolving the contradiction between production speed and mechanical properties
Solution Approach 2:
The patent employs composite materials by creating a particulate system with specific composition: a polymer matrix (from photopolymerized resin) containing unreacted monomers and oligomers that can undergo secondary moisture-curing. This composite structure allows the material to exhibit both rapid initial set (for productivity) and continued strength gain (for mechanical properties)
2Adaptability or versatility
If conventional additive manufacturing resins are used, then prototyping can be achieved, but real-world applications are unsuitable due to limited mechanical properties
Solution Approach 1:
The patent changes the chemical parameters of the resin system by incorporating hydrolyzable groups (such as ester groups in the polymer matrix or unreacted monomers) that can undergo secondary reactions with moisture. This allows the material to transition from an initial light-cured state suitable for prototyping to a fully cured state with enhanced mechanical properties for real-world applications, thereby expanding adaptability without sacrificing strength
Solution Approach 2:
The patent applies preliminary action by first forming the basic structure through photopolymerization (light curing) which provides immediate handling capability for prototyping applications. The unreacted components remain in place to undergo subsequent moisture-curing, which continuously enhances mechanical properties. This two-stage approach allows immediate application for prototyping while preparing the material for eventual real-world use
3Productivity
If preformed articles are recycled through comminution, then reactive particulate material can be produced, but the process requires sustainable chemistry approaches
Solution Approach 1:
The patent converts what would normally be waste products (unreacted monomers and oligomers remaining after photopolymerization) into beneficial reactive components. These unreacted species, which would typically be discarded as harmful byproducts requiring special disposal, are instead utilized as the source of continued moisture-curing and strength development. This transforms a chemical sustainability challenge into a productivity advantage, as the recycling process inherently generates the reactive particulate material needed for continued manufacturing
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 enables the rapid production of three-dimensional objects with desirable structural and mechanical properties, suitable for real-world applications, by transforming preformed articles into reactive particulate materials that can be reused in additive manufacturing, enhancing the range of applications beyond prototyping.
Implementation Method 1
free radically polymerizing a single-cure resin (e.g., by exposure to light, heating, etc.) to produce a polymer
Data Source
AI summary
Provided herein are methods of making a reactive particulate material by free radically polymerizing a single-cure resin to produce a polymer, the resin comprising: a reactive blocked polyurethane prepolymer, a reactive blocked polyurea prepolymer, a reactive blocked polyurethane-polyurea copolymer, or a combination thereof, wherein said polymerizing is carried out by dispersive polymerization (e.g., an emulsion, suspension or dispersion polymerization process), to form said reactive particulate material. Methods of use of the reactive particulate material and material sets including the same are also provided.