Water-Soluble Polyester Support for FDM 3D Printing
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Solution Overview
Problem
Current support materials for 3D printing with FDM systems face challenges in being removable without aqueous strong alkaline solutions, which pose safety and environmental hazards, and are prone to foaming when exposed to high humidity, leading to reduced precision of the final 3D object.
Innovation Solution
A soluble support material composed of a polyester resin with aromatic dicarboxylic acid monomer units containing a sulfonate group, dicarboxylic acid monomer units without a sulfonate group, and diol monomer units, which can be dissolved in neutral water, preventing foaming and allowing for safe and efficient removal without alkaline solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If methacrylic acid copolymer is used as support material and aqueous strong alkaline solution is used for removal, then the support material can be removed, but safety hazards and environmental hazards increase
Solution Approach 1:
The patent changes the chemical parameters of the support material by incorporating sulfonate groups into the polyester resin structure. This chemical modification enables the support material to be removed using neutral water (pH 7) instead of strong alkaline solutions, thereby eliminating safety and environmental hazards while maintaining effective removability
Solution Approach 2:
The patent employs a disposable support material made of water-soluble polyester resin that is designed to be easily removed after serving its temporary support function. The material is intentionally made biodegradable and environmentally friendly, aligning with the principle of using safe, short-lived materials that can be disposed of without harmful impact
2Strength
If conventional support material is used, then it provides structural support, but it foams when exposed to high humidity leading to reduced precision
Solution Approach 1:
The patent uses a composite polyester resin structure combining hydrophobic aromatic hydrocarbon groups (for strength and moisture resistance) with hydrophilic sulfonate groups (for water solubility). This composite structure prevents foaming in high humidity while maintaining structural support capability and enables controlled dissolution in neutral water
Solution Approach 2:
The patent applies local quality by creating regions with different hydrophobicity within the polymer chain - hydrophobic aromatic groups provide structural integrity and moisture resistance, while localized sulfonate groups provide water solubility. This spatial differentiation of properties prevents foaming while enabling controlled dissolution
3Ease of operation
If support material is designed for easy removal, then removal process is simplified, but the support material may compromise structural integrity during printing
Solution Approach 1:
The patent carefully controls the proportion of sulfonate groups (0.1-10 mmol/g) to achieve the right balance between structural strength during printing and water solubility for easy removal. The molecular weight is also optimized (10,000-100,000) to ensure adequate strength while maintaining solubility, creating a narrow parameter window that satisfies both 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 proposed solution enables the support material to be dissolved quickly in neutral water, preventing foaming and maintaining the precision of the 3D object, while ensuring safety and environmental sustainability by avoiding the use of strong alkaline solutions.
Implementation Method 1
a soluble material comprising a polyester resin comprising one or more aromatic dicarboxylic acid monomer units A with a sulfonate group
Implementation Method 2
The method utilizes that carboxylic acid in the methacrylic acid copolymer is neutralized by an alkali and dissolved in an aqueous strong alkaline solution
Data Source
AI summary
A soluble material for three-dimensional modeling, which is used as a raw material of a support material for supporting a three-dimensional object when the three-dimensional object is produced, using a 3D printer of a FDM system, includes a polyester resin including one or more aromatic dicarboxylic acid monomer units A with a sulfonate group, one or more dicarboxylic acid monomer units B without a sulfonate group, and one or more diol monomer units. The proportion of the aromatic dicarboxylic acid monomer unit(s) A in the total of all dicarboxylic acid monomer units is from 10 to 70 mol %. The soluble material has hygroscopicity resistance while the material is large in dissolution rate into any neutral water and removable speedily from a precursor of the three-dimensional object without using any aqueous strong alkaline solution.