Soft-Material 3D Printing With Removable Support Inks for Complex Shapes
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Solution Overview
Problem
Existing 3D printing methods struggle to produce complex-shaped three-dimensional objects made of soft materials with good fabrication accuracy, as bioinks often flow out or deform before gelling, especially under gravity.
Innovation Solution
A method involving the individual discharge of a model material ink containing a photocrosslinkable polymer and a support material ink with a crosslinking factor, followed by photocuring and removal of the support material ink, using inks that are free or substantially free of photopolymerization initiators and photocrosslinkable polymers, and incorporating water-soluble or water-dispersible polymers for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If bioink is discharged from a nozzle to form complex-shaped three-dimensional objects, then the ability to create artificial organs with bridges or holes is improved, but the bioink flows out (drips) and deforms under gravity before gelling, resulting in collapse and poor fabrication accuracy
Solution Approach 1:
The patent applies preliminary action by discharging a support material ink containing crosslinking factors before or simultaneously with the model material ink. This support material forms a temporary structural framework that prevents gravity-induced collapse and deformation of the model material before it gels, enabling accurate fabrication of complex shapes with bridges and holes.
Solution Approach 2:
The support material ink acts as an intermediary between the model material ink and the final gelled structure. It provides temporary mechanical support and shape maintenance during the critical period before photocuring, allowing the model material to be discharged in complex configurations without deforming, and is later removed after the structure is stable.
2Reliability
If the model material ink contains photopolymerization initiators to enable photocuring, then the gelling process is improved, but the model material ink may prematurely crosslink before discharge or during storage, reducing printability and dischargeability
Solution Approach 1:
The patent segments the crosslinking function into two separate components: the model material ink contains the photocrosslinkable polymer without photopolymerization initiators (maintaining printability), while the support material ink contains the crosslinking factors. This segmentation prevents premature crosslinking of the model material while ensuring reliable photocuring when the two inks are combined during printing.
Solution Approach 2:
The support material ink containing crosslinking factors serves as an intermediary that transfers the crosslinking function to the model material ink during the printing process. This allows the model material to remain uncrosslinked and printable until it is discharged and combined with the support material, at which point photocuring is activated.
3Strength
If the support material ink contains crosslinking factors to provide structural support, then the prevention of deformation under gravity is improved, but the support material must be removed after fabrication, adding process complexity
Solution Approach 1:
The patent applies parameter changes by selecting support materials with specific properties: water-soluble polymers (e.g., gelatin, starch, dextran) or polymers degradable by specific enzymes. These parameter choices enable the support material to be easily removed through simple washing or enzymatic treatment after fabrication, reducing process complexity despite the initial crosslinking function.
Solution Approach 2:
The support material is designed to be temporarily present during fabrication to provide structural support, then discarded through easy removal methods (water washing or enzymatic degradation) after the model material has gelled. This allows the support material to fulfill its temporary function and be recovered/removed without adding significant process complexity.
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
This approach enables the production of complex-shaped three-dimensional objects with improved fabrication accuracy, suitable for applications in regenerative medicine, by preventing deformation and ensuring precise structure formation.
Implementation Method 1
photocuring the discharged photocrosslinkable polymer
Implementation Method 2
the water-soluble polymer or water-dispersible polymer is capable of forming an aqueous gel that can interact with an ionic compound to aggregate or reduce its viscosity
Data Source
Figure 1(a)~1(c)
Figure 2~4
Figure 5~7
AI summary
Provided are a method for producing a three-dimensional object and an ink set for producing a three-dimensional object, which can produce even, for example, a complex-shaped three-dimensional object made of a soft material with good fabrication accuracy. The present invention relates to a method for producing a three-dimensional object, including individually discharging (a) a model material ink containing a photocrosslinkable polymer and (b) a support material ink containing a support material and a first crosslinking factor, photocuring the discharged photocrosslinkable polymer, and removing an object of the support material ink.