ROMP 3D Inkjet Printing Formulation for Nozzle Clogging
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Solution Overview
Problem
Current 3D inkjet printing technologies face limitations in using ring-opening metathesis polymerization (ROMP) materials due to rapid curing at ambient conditions, which restricts their application in 3D inkjet processes requiring specific viscosity ranges for inkjet printing heads.
Innovation Solution
The development of methodologies that enable the use of ROMP formulations in 3D inkjet printing by incorporating unsaturated cyclic monomers, catalysts, and toughening agents, along with activators and inhibitors, to control the polymerization process and maintain suitable viscosity for inkjet printing, allowing for the production of materials with high thermal resistance and toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ROMP monomers and catalysts are pre-mixed to enable polymerization, then high thermal resistance and mechanical performance are achieved, but rapid curing causes nozzle clogging and increases viscosity beyond jettable ranges
Solution Approach 1:
The formulation is segmented into separate functional components: ROMP monomers, catalysts, and inhibitors are kept as distinct entities within the composition. The catalyst and inhibitor are pre-positioned in the formulation but remain dormant until the printing process, allowing the material to maintain low viscosity during storage and jetting while enabling controlled polymerization during fabrication.
Solution Approach 2:
The catalyst and inhibitor are incorporated into the formulation in advance but kept inactive during storage and jetting. The inhibitor prevents premature polymerization, allowing the material to be prepared and stored ready for printing without curing. During the printing process, the inhibitor is consumed or deactivated, allowing the catalyst to initiate polymerization and achieve the desired mechanical properties.
2Temperature
If ROMP materials are used to achieve high thermal resistance, then exceptional mechanical performance is obtained, but the viscosity becomes too high for inkjet printing heads
Solution Approach 1:
The formulation utilizes parameters such as monomer selection (e.g., norbornene derivatives), catalyst type (e.g., organometallic complexes), and inhibitor concentration to control the timing and rate of polymerization. These parameter changes allow the material to maintain low viscosity during jetting while enabling rapid curing after deposition to achieve high thermal resistance.
Solution Approach 2:
An inhibitor acts as an intermediary substance that temporarily blocks the catalytic activity, preventing premature polymerization and maintaining low viscosity for jetting. The inhibitor mediates between the monomer and catalyst, allowing the formulation to remain processable during printing while enabling subsequent curing to achieve the desired thermal and mechanical properties.
3Productivity
If catalysts are added to initiate ROMP polymerization, then rapid curing is achieved, but the material cannot be processed through inkjet printing heads
Solution Approach 1:
An inhibitor is added to the formulation to counteract the catalytic activity before printing. This preliminary anti-action prevents premature polymerization that would otherwise occur upon mixing monomers and catalysts, allowing the material to maintain processable viscosity during storage and jetting while enabling rapid curing after deposition when the inhibitor is consumed or deactivated.
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
Enables the fabrication of three-dimensional objects with exceptional mechanical performance, including high thermal resistance, impact resistance, and chemical solvent resistance, while avoiding nozzle clogging issues associated with pre-mixed ROMP monomers and catalysts.
Implementation Method 1
ring-opening metathesis polymerization (ROMP) for producing three-dimensional objects
Implementation Method 2
catalysts, and toughening agents, along with activators and inhibitors, to control the polymerization process
Data Source
AI summary
Methods for fabricating three-dimensional objects by 3D-inkjet printing technology are provided. The methods utilize curable materials that polymerize via ring-opening metathesis polymerization (ROMP) in combination with toughening agents for fabricating the object. Systems suitable for performing these methods and kits containing modeling material formulations usable in the methods are also provided.