3D Printing Ultra-High Viscosity Rubber Without Phase Change
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Solution Overview
Problem
Current 3D printing technologies cannot effectively work with materials that are liquid at room temperature but have ultra-high viscosity, and they struggle to produce structures with high elasticity, stability, and tensile strength without phase change during processing.
Innovation Solution
A process involving the application and curing of at least two layers of materials with high Mooney viscosity (>10 ME at 60°C and <200 ME at 100°C) on a substrate, allowing for the creation of three-dimensional structures without phase transition, using techniques like extrusion and curing to achieve high mechanical stability and rubbery properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 3D printing technologies are used with ultra-high viscosity liquid materials, then the materials cannot be effectively processed, but the invention enables processing of materials with Mooney viscosity >10 ME at 60°C through controlled extrusion and curing
Solution Approach 1:
The patent applies parameter changes by controlling temperature and viscosity relationships during processing. Specifically, the material is processed at temperatures where its Mooney viscosity falls within the range of 10-200 ME, optimizing both extrudability and shape retention. The curing process is then applied to lock in the desired geometry, resolving the contradiction between processability and shape stability.
Solution Approach 2:
The invention uses preliminary action by applying a curing agent or initiating curing conditions during or immediately after extrusion, before the material fully sets. This preliminary curing action ensures that the ultra-high viscosity material maintains its deposited shape while still being workable during the layering process, enabling subsequent layers to be applied without distortion.
2Strength
If materials with ultra-high viscosity are used to achieve high elasticity and stability, then the materials cannot be extruded without phase change, but the invention enables extrusion and curing without phase transition
Solution Approach 1:
The patent utilizes parameter changes by precisely controlling the temperature and viscosity parameters during extrusion. The material is maintained at temperatures where its Mooney viscosity is >10 ME at 60°C, ensuring it remains in a liquid state suitable for extrusion without requiring phase change. After extrusion, curing is initiated to achieve the desired elastic and mechanical properties.
Solution Approach 2:
The invention replaces the conventional mechanical extrusion system (which relies on melting and flowing thermoplastics) with a system that extrudes ultra-high viscosity liquids and cures them in place. This substitution eliminates the need for phase change while achieving similar or superior mechanical properties through chemical curing rather than thermal processing.
3Temperature
If conventional extrusion methods are used for thermoplastics, then high temperatures (185°C to above 400°C) are required for liquification, but the invention enables processing at lower temperatures without liquification
Solution Approach 1:
The patent applies parameter changes by operating at fundamentally different temperature parameters than conventional thermoplastic extrusion. Instead of heating materials to 185-400°C for melting, the invention processes ultra-high viscosity liquids at much lower temperatures where the material remains liquid but maintains sufficient viscosity for shape retention. The curing process then occurs at these lower temperatures, preserving shape accuracy without thermal distortion.
4Stability of the object's composition
If materials are cured to achieve temperature shape stability, then the cured material becomes rubbery and stable, but the curing process must not lose the intended shape
Solution Approach 1:
The invention uses preliminary action by ensuring that the material is properly deposited and positioned before curing begins. The extrusion and layering processes are completed with the material in its ultra-high viscosity liquid state, establishing the precise geometry. Only after the structure is fully formed does the curing process begin, locking in the shape while developing the rubbery, temperature-stable properties.
Solution Approach 2:
The patent applies parameter changes by controlling the curing conditions to match the deposited geometry. The curing process parameters (temperature, time, curing agent concentration) are optimized to achieve complete crosslinking and temperature shape stability without causing shrinkage, warping, or other shape deviations. This results in cured parts that maintain high manufacturing precision while gaining elastic and thermal stability.
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 production of three-dimensional structures with high elasticity and stability, maintaining shape without phase change, and achieving rubbery material properties with enhanced mechanical properties and temperature-dependent modulus.
Implementation Method 1
curing the materials, wherein at least one of the materials has a Mooney viscosity of >10 ME at 60° C.
Implementation Method 2
Feed rods of the polymer are extruded from an extrusion cylinder using a piston which is displaced into a cylinder
Data Source
AI summary
A process is described for producing a three dimensional structure, the process including the following steps a) applying of at least a first material M1 onto a substrate to build a first layer L1 on the substrate; b) layering of at least one further layer Ly of the first material M1 or of a further material Mx onto the first layer L1, wherein the at least one further layer Ly covers the first layer L1 and/or previous layer Ly-1 at least partially to build a precursor of the three dimensional structure; c) curing the precursor to achieve the three dimensional structure; wherein at least one of the materials M1 or Mx provides a Mooney viscosity of >10 ME at 60° C. and of <200 ME at 100° C. before curing. Also, a three dimensional structure is described which is available according to the process according to the invention.