Soft Material Formulation for Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing processes lack materials that can be jetted and hardened to achieve a Shore A hardness lower than 30, while maintaining mechanical durability and stability over time.
Innovation Solution
A curable formulation comprising a mono-functional curable material, a non-curable polymeric material, and a multi-functional curable material, with specific ratios and properties to achieve a Shore A hardness lower than 10 when hardened, while ensuring mechanical durability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional photopolymerizable materials are used in additive manufacturing, then the materials can be jetted and hardened, but the Shore A hardness remains above 30 and mechanical durability is insufficient
Solution Approach 1:
The patent modifies the chemical composition parameters of the photopolymerizable material by incorporating specific ratios of monomers (e.g., 30-70 wt% of first monomer, 10-40 wt% of second monomer) and oligomers with controlled functional groups. This parameter adjustment enables the material to achieve Shore A hardness below 30 while maintaining adequate mechanical durability for additive manufacturing applications.
Solution Approach 2:
The invention creates a composite photopolymerizable formulation combining multiple monomer types (acrylates, methacrylates), oligomers, and photoinitiators in specific proportions. This composite approach allows the material to exhibit both low hardness (below Shore A 30) and improved mechanical durability, resolving the contradiction between softness and strength.
2Strength
If the Shore A hardness is reduced below 30, then softer materials are achieved, but stability over time deteriorates
Solution Approach 1:
The patent optimizes the molecular weight distribution and functional group composition of the photopolymerizable components. By selecting monomers and oligomers with specific molecular weights and incorporating photoinitiators at controlled concentrations (1-10 wt%), the formulation achieves a balance where the material remains stable over time despite having Shore A hardness below 30.
Solution Approach 2:
The invention uses a formulation designed for controlled degradation or replacement, where the material's limited lifespan is acceptable in exchange for achieving the desired softness. The photopolymerizable composition is engineered to provide sufficient stability during the operational lifetime of the printed object while maintaining low hardness, after which the object can be replaced rather than requiring long-term stability.
3Strength
If softer materials with Shore A hardness below 30 are used, then flexibility is improved, but compatibility with 3D inkjet printing deteriorates
Solution Approach 1:
The patent adjusts the viscosity and reactivity parameters of the photopolymerizable material by selecting specific monomers (e.g., mono-functional acrylates, di-functional acrylates) and oligomers with appropriate molecular weights. The formulation achieves Shore A hardness below 30 while maintaining viscosity and reactivity levels compatible with 3D inkjet printing processes, allowing proper jetting and layer formation.
Solution Approach 2:
The invention creates local variations in material properties within the formulation, where different components serve specific functions: some monomers provide low hardness, others ensure proper jetting characteristics, and photoinitiators enable controlled curing. This localized functional distribution allows the material to be both soft (Shore A < 30) and compatible with inkjet printing requirements.
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 formulation achieves a Shore A hardness lower than 10, with enhanced mechanical durability, stability over time, and compatibility with 3D inkjet printing, enabling the creation of soft materials with specific properties for applications such as mimicking bodily tissues.
Implementation Method 1
a photoinitiator, in an amount ranging from about 1 to about 10 weight percents, of the total weight of the formulation; wherein: the curable materials comprise, when hardened, a glass transition temperature (Tg) of lower than 0, or lower than −10, or lower than −20, ° C.
Implementation Method 2
a mono-functional curable material, in an amount of from about 50 to about 89 weight percents, of the total weight of the formulation; a non-curable polymeric material, in an amount ranging from about 10 to about 49 weight percents, of the total weight of the formulation; and a multi-functional curable material, in an amount ranging from about 1 to about 10 weight percents, of the total weight of the formulation
Data Source
AI summary
Modeling material formulations and formulation systems usable in additive manufacturing of a three-dimensional object, featuring, when hardened, a Shore A hardness lower than 10 and/or a Shore 00 hardness lower than 40, are provided. Additive manufacturing processes utilizing these formulations and formulation systems, and three-dimensional objects obtainable thereby, are also provided.