3D Printing Support Wax with Reactive Functional Groups
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Typical ink-jet 3D printing methods result in rough surfaces due to intermixing of support and build materials, leading to matte finishes, reduced wall thickness, and open porosity, which complicates the fabrication process and reduces yields.
Innovation Solution
A support composition comprising a wax with functional groups capable of reacting with build materials under actinic radiation, forming a cross-linked interface while remaining non-reactive itself, allowing for easy removal and preventing surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If typical ink-jet 3D printing methods are used, then support material can be deposited and removed, but surface roughness and porosity occur due to intermixing at the interface
Solution Approach 1:
The support composition is designed with spatially differentiated properties: the bulk support material remains non-crosslinked and removable, while the interface region forms a crosslinked non-removable layer. This local differentiation prevents support material extraction at the interface, eliminating surface roughness and porosity while maintaining ease of support removal elsewhere.
Solution Approach 2:
The support composition combines multiple components (wax, functional groups, photoinitiator) to create a composite material with dual functionality. The composite structure enables selective crosslinking at the interface through reaction with build material, while the bulk remains extractable, resolving the contradiction between adhesion and removability.
2Ease of operation
If support material is removed after printing, then the 3D article is released, but extracted support material creates rough surfaces and open porosity
Solution Approach 1:
The support composition is segmented into two functional zones: a bulk region that remains non-crosslinked and easily removable, and an interface region that crosslinks with the build material to form a permanent bond. This segmentation allows complete support removal without compromising surface integrity, as the crosslinked interface layer prevents support material extraction.
3Strength
If build material and support material intermix at the interface, then adhesion is achieved, but matte finish and reduced wall thickness occur
Solution Approach 1:
The chemical state of the support composition is changed through selective crosslinking: the interface region undergoes crosslinking reaction with the build material to enhance adhesion strength, while the bulk remains in its original state. This parameter change (crosslinking degree) allows strong adhesion without the harmful effects of intermixing, maintaining uniform wall thickness.
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 prevents the formation of rough, porous surfaces by creating a cross-linked interface that remains non-extractable, maintaining the bulk support material's non-crosslinked state for easy removal, thus enhancing the surface finish and reducing porosity in 3D ink-jet printed articles.
Implementation Method 1
a wax including at least one functional group capable of reacting with a build material used in the 3D deposition method, when exposed to an actinic radiation
Implementation Method 2
exposing the plurality of support layers and the plurality of build layers to an actinic radiation
Data Source
AI summary
A composition suitable for forming a support using a three-dimensional (3D) deposition method is presented. The composition includes a wax including at least one functional group capable of reacting with a build material used in the 3D deposition method, when exposed to an actinic radiation, wherein the functional group is itself substantially non-reactive to the actinic radiation. A method of forming a three dimensional (3D) article is also presented.