Two-Part Reactive Substance Fabrication for Dental Implants
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Solution Overview
Problem
Current object fabrication techniques, such as rapid prototyping, face limitations due to starting materials that are either weak or brittle in their solid state, or have limited material properties, leading to issues like brittleness, warping, and the inability to produce precision objects like dental models or implants due to hygroscopicity and residual toxic chemicals.
Innovation Solution
A method involving the application of at least two substances that chemically react upon contact to form sections of an object, allowing for the creation of a wide range of materials with improved properties, such as polymeric or metallic substances, which can be tailored for specific applications by altering the substances or their ratios, enabling the production of durable and precise objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If photopolymer is used as starting material, then object can be formed by curing, but the cured object becomes brittle and warps when exposed to ultraviolet light
Solution Approach 1:
The invention changes the chemical parameters of the starting material from photopolymer to two-part reactive substances (such as epoxy and hardener, or polyester and catalyst). This parameter change eliminates the brittleness and warping issues associated with cured photopolymers while maintaining the layer-by-layer fabrication capability.
Solution Approach 2:
The invention uses composite material systems where two different substances are applied in sequence or mixture to form the object layer. This composite approach (e.g., epoxy-resin systems, polyester-catalyst systems) provides superior mechanical properties and dimensional stability compared to single-component photopolymers, resolving the reliability issue while preserving manufacturability.
2Ease of manufacture
If photopolymer is used as starting material, then object can be formed by curing, but the cured object is hygroscopic and bloats in moist environments
Solution Approach 1:
The invention changes the chemical composition parameters from hygroscopic photopolymer systems to moisture-resistant reactive polymer systems such as epoxy or polyester resins. These alternative materials inherently resist moisture absorption, preventing bloating while maintaining ease of manufacture through similar application processes.
3Ease of manufacture
If photopolymer is used as starting material, then object can be formed by curing, but residual toxic chemicals remain and objects cannot be implanted into the body
Solution Approach 1:
The invention changes the chemical parameters from photopolymer systems containing residual toxic photoinitiators and monomers to two-part reactive systems (epoxy-hardener, polyester-catalyst) that undergo complete chemical reaction. This parameter change eliminates residual toxic chemicals, making the fabricated objects biocompatible and suitable for medical implants while preserving ease of manufacture.
4Ease of manufacture
If powder material is used as starting material, then object can be formed by hardening with binder, but the object is heterogeneous and porous with limited strength
Solution Approach 1:
The invention changes the physical state parameter of the starting material from powder to liquid form. This parameter change enables the formation of homogeneous, non-porous structures with superior strength, as the liquid reactive substances can fully wet and bond without the heterogeneity and porosity inherent in powder-binder systems.
5Ease of manufacture
If powder material is used as starting material, then object can be formed by hardening with binder, but the resolution is low at least 0.2 mm which is unsuitable for fine objects
Solution Approach 1:
The invention changes the physical state parameter from powder to liquid, enabling significantly finer resolution. Liquid reactive substances can be deposited in thin, uniform layers with precise control, achieving manufacturing precision far below the 0.2 mm limitation of powder-based processes, thus enabling fabrication of fine detailed objects while maintaining ease of manufacture.
6Ease of manufacture
If wax or plastic with low viscosity is used as starting material, then object can be formed by melting and applying, but the solid state is weak or brittle with limited utility
Solution Approach 1:
The invention changes the chemical composition parameters from simple wax or plastic materials to reactive polymer systems (epoxy, polyester, polyurethane). This parameter change transforms the solid state properties from weak and brittle to strong and durable, while the low-viscosity liquid state before reaction maintains ease of manufacture through simple application processes.
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 expands the range of materials available for object fabrication, enabling the creation of durable, precise, and versatile objects with improved properties, such as toughness, hardness, and chemical resistance, suitable for applications like jewelry, dental restorations, and medical implants.
Implementation Method 1
applying at least two substances within an area having the shape of the section being formed, the at least two substances being able to chemically react upon contact with each other to form the section
Data Source
AI summary
The invention relates to a method for making an object, the method comprising forming a plurality of sections of the object, wherein the formation of each of the plurality of sections comprises applying at least two substances within an area having the shape of the section being formed, the at least two substances being able to chemically react upon contact with each other to form the section. The invention also relates to an apparatus for making an object, the apparatus comprising: an applicator arranged to apply at least two substances within an area having a shape of a section of the object being made, the at least two substances being able to chemically react upon contact with each other to form the section.