3D Printing Resin Separation Effect via Saturated Fatty Acids
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Solution Overview
Problem
Current 3D printing resins used in the dental sector often result in objects that bond with dental models due to interpenetrating networks, leading to difficulties in detachment, inhomogeneous surfaces, and mechanical retention issues, which can cause fitting problems and require rework or remaking of orthodontic appliances.
Innovation Solution
A 3D printing resin containing greater than 5% by weight of saturated fatty acids or their esters with a chain length less than 20 C, which provides an inherent separation effect, ensuring homogeneous surfaces and transparent resin systems that allow for better process control during printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wax particles are added to the resin as filler to reduce adhesion, then separation effect is improved, but particles separate and sink to the bottom, causing inhomogeneous surfaces and faulty build jobs
Solution Approach 1:
The patent changes the chemical parameters of the resin system by incorporating saturated fatty acids and their esters with specific chain lengths (C1-C20). This chemical modification provides inherent separation properties without the physical separation issues of wax particles, as the fatty acid components remain molecularly dispersed and integrated within the resin matrix throughout the printing process.
Solution Approach 2:
The saturated fatty acids and esters act as intermediary substances that mediate between the resin matrix and the scattered plastic material. These compounds provide the separation effect through their chemical properties, creating a barrier layer that prevents adhesion without requiring physical filler particles that would separate and sink.
2Reliability
If wax particles are used to achieve separation effect, then adhesion is reduced, but resin viscosity increases and mechanical properties deteriorate
Solution Approach 1:
The patent modifies the resin's chemical composition by incorporating saturated fatty acids and esters with optimized chain lengths (C1-C20). This parameter change provides separation functionality while maintaining acceptable viscosity and mechanical properties, as the molecularly dispersed fatty acid components do not create the bulkiness and viscosity increase associated with particulate fillers.
3Reliability
If wax particles are added to the resin, then separation effect is improved, but resin becomes opaque, preventing build process control
Solution Approach 1:
The patent changes the optical parameters of the resin by using molecularly dispersed saturated fatty acids and esters instead of particulate wax fillers. This parameter change maintains resin transparency, allowing UV light to penetrate through the resin during stereolithography printing processes, thereby enabling real-time build process control and monitoring.
4Reliability
If manual application of separator gel is used, then separation effect is achieved, but application is time-consuming and inhomogeneous, especially on undercuts and in interdental spaces
Solution Approach 1:
The patent merges the separation function with the base resin material itself. By incorporating saturated fatty acids and esters directly into the 3D printing resin formulation, the separation effect becomes an inherent property of the printed object, eliminating the need for separate manual application steps and ensuring uniform distribution across all surface areas including undercuts and interdental spaces.
Solution Approach 2:
The resin system provides its own separation function through the inherent properties of the saturated fatty acid and ester components. The printed objects automatically exhibit separation effects without requiring external separator gels or additional manual application steps, making the system self-sufficient and significantly improving productivity.
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 resin achieves a significant increase in separation effect, allowing for easy detachment of printed objects from dental models, smoother surfaces, and improved mechanical properties, enabling higher construction speeds and easier cleaning with lower viscosity.
Implementation Method 1
the resin achieves a significant increase in separation effect, allowing for easy detachment of printed objects from dental models
Implementation Method 2
ensuring homogeneous surfaces and transparent resin systems that allow for better process control during printing
Implementation Method 3
enabling higher construction speeds and easier cleaning with lower viscosity
Data Source
AI summary
The present invention relates to a 3D printing resin comprising a monomer or oligomer having at least one acrylate or methacrylate subunit and an initiator. The 3D printing resin is characterized in that it comprises a saturated fatty acid or a carboxylic acid ester, whereby a separation effect is achieved with respect to other plastics. The invention further relates to a polymer comprising the monomers and oligomers described above in polymerized form and a saturated fatty acid or carboxylic acid ester. If only 60-80% of the double bonds of the monomer or oligomer are reacted, a green compact can be obtained. The invention also provides a kit-of-parts system comprising the above-described 3D printing resin for producing a polymer with a separation effect and a powder component and a liquid component for producing a plastic. Finally, the invention also relates to methods for producing a molded part with a separation effect and to a method for producing a molded part, wherein the molded part is complementary to another molded part. In the latter method, one molded part is made from the 3D printing resin described above and the other molded part is made from a plastic.