Self-Healing Photocurable Polymer Ink for Additive Manufacturing
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Solution Overview
Problem
Existing lattice structures in engineering applications lack the ability to modulate properties and heal from fractures, as current materials are not photocurable and self-healable, and healing of lattice structures is challenging due to the need for precise contact of fracture interfaces, which is difficult for complex architectures.
Innovation Solution
Development of a photocurable, self-healable, and shape-memorizable polymer ink for additive manufacturing, which incorporates disulfide bonds for fracture healing and acrylate groups for photocuring, enabling the creation of lattice structures that can heal fatal fractures and recover shape-memory properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If photocurable materials are used for additive manufacturing of lattice structures, then manufacturing precision and productivity are improved, but the ability to self-heal fractures is lost
Solution Approach 1:
The patent combines photocurable acrylate groups with self-healing disulfide bonds in a single polymer system. The acrylate groups enable photopolymerization for additive manufacturing, while the disulfide bonds provide reversible fracture healing capability, merging two previously incompatible material functions into one unified material system.
Solution Approach 2:
The invention creates a composite polymer material containing both acrylate functional groups for photocuring and disulfide bonds for self-healing. This composite material structure allows simultaneous achievement of additive manufacturability and fracture repairability, resolving the contradiction between these two features.
2Strength
If high-strength self-healable polyurethane is used, then strength is improved, but photocuring capability for additive manufacturing is lost
Solution Approach 1:
The patent introduces local acrylate functional groups into the polyurethane polymer chains at specific positions. These localized acrylate groups enable photocuring reactivity while the bulk polyurethane structure maintains its high strength properties through the disulfide bond network, allowing simultaneous achievement of strength and photocuring capability.
Solution Approach 2:
The invention modifies the chemical parameters of the polyurethane by incorporating acrylate-functionalized components. This parameter change enables the material to undergo photopolymerization while preserving the mechanical strength characteristics of the polyurethane backbone, bridging the gap between high-strength self-healable materials and photocurable materials.
3Manufacturing precision
If fracture interfaces are manually contacted for healing, then healing precision is improved, but device complexity and ease of operation worsen for complex lattice architectures
Solution Approach 1:
The patent enables the lattice structure to perform self-alignment and self-healing of fracture interfaces through the shape memory effect. When heated above the transition temperature, the material autonomously recovers its original shape, bringing fracture surfaces into contact without requiring manual intervention or complex alignment mechanisms, thus reducing operational complexity while maintaining healing precision.
Solution Approach 2:
The invention utilizes the phase transition of the shape memory polymer at its transition temperature to enable automatic fracture interface alignment. Upon heating, the material transitions from a rigid state to a compliant state, allowing fracture surfaces to realign through elastic recovery, eliminating the need for manual contact and reducing the complexity of the healing process for complex architectures.
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 resulting lattice structures can fully restore stiffness and strength over multiple healing cycles, enabling reversible configuration transformations and smart modulation of properties, suitable for applications in aircraft panels, body armor, and acoustic modulators.
Implementation Method 1
incorporates disulfide bonds for fracture healing and acrylate groups for photocuring
Implementation Method 2
incorporates disulfide bonds for fracture healing
Implementation Method 3
shape-memorizable polymers for additive manufacturing
Data Source
AI summary
A method of making an ink for use in additive manufacturing of a self-healable and shape-memorizable product includes mixing a diol with isophorone diisocyanate, dimethylacetamide, and dibutyltin dilaurate to form a first solution. The method further includes mixing the first solution with 2-Hydroxyethyl disulfide to form a second solution. The method further includes mixing the second solution with 2-Hydroxyethyl methacrylate to form a third solution. The method further includes mixing the third solution with a tributylphosphine, a photoinitiator, and a photoabsorber to facilitate additive manufacturing of the ink.