Transparent Biocompatible 1K Silicone for DLP 3D Printing
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Solution Overview
Problem
Conventional 3D printing materials for DLP methods lack biocompatibility, transparency, and high siloxane content, limiting their application in medical and dental fields, particularly for products like earpieces, gingival masks, and orthodontic appliances.
Innovation Solution
A low-viscosity, transparent, and biocompatible 1K silicone resin material with at least 50% siloxane groups, comprising monomeric or oligomeric dimethacrylate, cyclic (meth)acrylates, silicone oil, fillers, and photoinitiators, which can be cured under UV light for producing elastic and biocompatible three-dimensional medical products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional elastic materials for 3D printing are used, then they can be printed using layer-by-layer construction, but they lack biocompatibility, transparency, and high siloxane content
Solution Approach 1:
The patent uses composite materials by combining siloxane groups with (meth)acrylate functional groups in a single resin system. This creates a material that exhibits both the biocompatibility and elasticity of silicones and the UV-curing capability of (meth)acrylates, enabling DLP 3D printing of medical-grade elastic parts
Solution Approach 2:
The patent modifies the chemical parameters of conventional printing resins by incorporating siloxane groups and adjusting the ratio of (meth)acrylate to siloxane content. This parameter change transforms the material properties to achieve both printability and medical-grade biocompatibility simultaneously
2Productivity
If silicone-like elastic materials with low siloxane content are used, then they can be printed additively, but they lack transparency and biocompatibility
Solution Approach 1:
The patent increases the siloxane content parameter to at least 50% while maintaining the (meth)acrylate functionality needed for UV curing. This parameter optimization enables the material to achieve transparency and biocompatibility without sacrificing additive manufacturing capability
Solution Approach 2:
The patent creates a composite resin system where siloxane groups provide transparency and biocompatibility while (meth)acrylate groups enable UV-initiated polymerization. This composite approach allows all desired properties to coexist in a single printable material
3Reliability
If materials with high siloxane content are used, then transparency and biocompatibility improve, but curing speed and mechanical strength may be compromised
Solution Approach 1:
The patent optimizes the (meth)acrylate functionality parameter by using bifunctional or polyfunctional (meth)acrylate groups. This increases the crosslinking density and curing efficiency, enabling rapid UV curing even with high siloxane content that would otherwise slow down the reaction
4Strength
If the resin material has high viscosity, then it provides good mechanical strength, but it reduces flowability and printing precision
Solution Approach 1:
The patent adjusts the viscosity parameter by selecting appropriate siloxane chain lengths and (meth)acrylate group configurations. This creates a balanced viscosity range that ensures adequate flowability for DLP printing precision while maintaining sufficient mechanical strength in the cured state
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 material achieves rapid curing, high mechanical strength, and flexibility, enabling the production of transparent, elastic, and biocompatible medical devices without the need for subsequent heat treatment, while maintaining low viscosity and flowability suitable for precise DLP printing.
Implementation Method 1
The invention provides a composition comprising... photoinitiators... that can be polymerized by a photoinitiator or a combination of a plurality of photoinitiators in the UV light range and thus cured
Data Source
AI summary
A transparent, elastic, and biocompatible 1K silicone for additive manufacturing that can be printed by stereolithographic processes, includes at least25-75% by weight of a monomeric or oligomeric dimethacrylate based on silicone or silicone urethanes having a viscosity of <100 Pa·s,20-50% by weight of one or more monomeric/oligomeric cyclic (meth)acrylates having a viscosity of <0.5 Pa·s,1-25% by weight of silicone oil having a viscosity of <1 Pa·s,0.5-20% by weight of fillers with a particle size of <100 μm,0.1-5% by weight of one or a combination of a plurality of photoinitiators whose absorption is in the wavelength range of the laser beam or irradiation source used.