Soluble Support Material for FDM 3D Printing
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Solution Overview
Problem
Fused deposition modeling (FDM) 3D printing systems face challenges with support materials that require strong alkaline solutions for removal, leading to environmental hazards and erosion of three-dimensional objects, and existing water-soluble materials like poly(2-ethyl-2-oxazoline) suffer from moisture absorption and precision issues due to high water affinity.
Innovation Solution
A soluble material for three-dimensional modeling comprising a thermoplastic resin with hydrophilic groups and an organic salt compound, represented by the formula (R1—SO3−)nXn+, which allows for rapid dissolution in neutral water without using strong alkaline solutions, providing sufficient adhesive properties and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If poly(2-ethyl-2-oxazoline) is used as support material due to its water solubility, then the support material can be removed by neutral water without strong alkaline solutions, but the material absorbs moisture from air due to high water affinity, causing foaming during heating and printing, which damages precision
Solution Approach 1:
The patent uses a copolymer composed of a first monomer unit (providing water solubility through hydrophilic groups like carboxyl or sulfonate) and a second monomer unit (providing hydrophobicity through alkyl groups). This composite structure allows the material to dissolve in neutral water for easy removal while the hydrophobic components reduce moisture absorption from air, preventing foaming during printing and maintaining dimensional precision.
2Ease of manufacture
If methacrylic acid copolymer is used as support material, then the support material can be removed by chemical reaction with strong alkaline solution, but the strong alkaline solution is hazardous to people and environment, and erodes the three-dimensional object, limiting material choices
Solution Approach 1:
The patent changes the chemical parameters of the support material by incorporating ionizable groups (carboxyl or sulfonate) that can be neutralized by mild alkaline substances like ammonia water or bicarbonate solutions. This allows the support material to be removed through controlled chemical reaction at near-neutral pH, avoiding the need for strong alkaline solutions and their associated hazards to people, environment, and the three-dimensional object.
3Productivity
If support material with high water affinity is used to enable water-based removal, then the support material dissolves easily in neutral water, but the material absorbs water from air during storage and printing, causing foaming when heated and scattered by high temperature, remarkably damaging precision
Solution Approach 1:
The patent creates a balanced copolymer structure where hydrophilic monomer units (providing fast dissolution in water) are combined with hydrophobic monomer units (containing alkyl groups that resist moisture absorption). This composite approach enables rapid dissolution in neutral water for high productivity while the hydrophobic segments prevent excessive moisture uptake from air, eliminating foaming during heating and maintaining dimensional precision.
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 solution enables the production of three-dimensional objects with improved precision and reduced environmental impact by using a support material that is easily removable in neutral water, maintaining structural integrity and adhesive properties during the FDM process.
Implementation Method 1
an organic salt compound, represented by the formula (R1—SO3−)nXn+, wherein R1 represents a hydrocarbon group that optionally has a substituent group and that has 1 to 30 carbon atoms; n represents a number of 1 or 2; when n is 1, Xn+ represents a sodium ion, a potassium ion, a lithium ion, an ammonium ion, or a phosphonium ion
Implementation Method 2
poly(2-ethyl-2-oxazoline), which is contained in the soluble material for three-dimensional modeling, is high in affinity with water. Thus, when the soluble material for three-dimensional modeling, which contains poly(2-ethyl-2-oxazoline), is exposed to a high humidity, this polymer absorbs water in the air
Implementation Method 3
When the soluble material for three-dimensional modeling, which contains poly(2-ethyl-2-oxazoline) containing the water and further contains others, is heated, melted, printed out and laminated, using a 3D printer of an FDM system, the water is vaporized and scattered by high temperature so that the soluble material is foamed
Data Source
AI summary
The present invention is a soluble material for three-dimensional modeling that is used as a material of a support material for supporting a three-dimensional object when the three-dimensional object is manufactured by a 3D printer of a fused deposition modeling system and that contains a thermoplastic resin having a hydrophilic group and an organic salt compound represented by a general formula (I) below: (R1—SO3−)nXn+ (I). According to the present invention, it is possible to provide a soluble material for three-dimensional modeling that is used for a support material and that is capable of suppressing the degradation of the modeling accuracy of a three-dimensional object when the three-dimensional object is manufactured by a 3D printer of a fused deposition modeling system, and has a high rate of dissolution to neutral water to be removable speedily from a precursor of the three-dimensional object without use of a strong alkaline aqueous solution.