Soluble 3D Printing Support Material Moisture Resistance
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Solution Overview
Problem
Fused deposition modeling (FDM) systems face challenges in maintaining accuracy and preventing foaming of three-dimensional objects when exposed to high humidity due to the soluble support materials used, which can lead to a decrease in the precision of the printed objects.
Innovation Solution
A soluble material for three-dimensional modeling is developed, comprising a polymer and a flat filler with a particle size of 0.1 µm to 20 µm and a thickness of 0.01 µm to 10 µm, selected from clay minerals or modified substances, which is used as a support material in FDM printing. This material is designed to suppress foaming and maintain accuracy by forming a network structure that enhances the interaction between the filler and the polymer, preventing deformation during moisture evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a soluble support material is used in FDM printing, then the support material can be easily removed after printing, but the three-dimensional object may foam and deform when exposed to high humidity
Solution Approach 1:
The invention uses a composite material consisting of a water-soluble polymer and a hydrophobic filler. The hydrophobic filler (such as silica, alumina, or titania particles) is dispersed within the water-soluble polymer matrix to create a composite support material that combines the solubility needed for easy removal with the hydrophobicity needed to prevent foaming and maintain dimensional accuracy when exposed to moisture.
2Ease of operation
If the support material is made water-soluble for easy removal, then post-processing is simplified, but the material becomes sensitive to moisture and causes foaming
Solution Approach 1:
The hydrophobic filler acts as an intermediary substance within the water-soluble polymer matrix. It mediates the interaction between the polymer and moisture, preventing direct absorption of water by the polymer while still allowing the polymer to remain soluble for easy removal. The hydrophobic filler particles create a physical barrier that blocks moisture from reaching and degrading the polymer structure.
3Manufacturing precision
If the filler particle size is reduced to improve printing precision, then the network structure forms better, but the filler content must be precisely controlled to maintain solubility
Solution Approach 1:
The invention optimizes the particle size parameters of the hydrophobic filler to a specific range (0.1-10 μm) and controls the filler content within a defined proportion (1-50 parts by mass per 100 parts of polymer). These parameter changes create an optimal balance where the filler particles are small enough to form an effective network structure for preventing foaming while large enough to maintain processingability and solubility. The specific parameter ranges simplify the control process by providing clear guidelines for formulation.
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 use of this soluble material effectively prevents foaming and maintains the accuracy of three-dimensional objects even when exposed to high humidity, ensuring precise printing results by enhancing the interaction between the filler and the polymer, thus improving the structural integrity and precision of the printed objects.
Implementation Method 1
forming a network structure that enhances the interaction between the filler and the polymer, preventing deformation during moisture evaporation
Implementation Method 2
enhances the interaction between the filler and the polymer
Implementation Method 3
The method utilizes that carboxylic acid in the methacrylic acid copolymer is neutralized by an alkali and dissolved in an alkaline aqueous solution
Implementation Method 4
the moisture evaporates due to high temperature and the soluble material for three-dimensional modeling is foamed
Data Source
AI summary
The soluble material for three-dimensional modeling of the present invention is a soluble material for three-dimensional modeling that is used as a material of a support material that supports a three-dimensional object when manufacturing the three-dimensional object with a fused deposition modeling type 3D printer. The soluble material for three-dimensional modeling contains at least one polymer and at least one filler. In the soluble material for three-dimensional modeling, the filler is a fibrous filler having a fiber length of 0.02 µm to 1, 000 µm and a fiber diameter of 0.0001 µm to 20 µm and/or a flat filler having a particle size of 0.1 µm to 20 µm and a thickness of 0.01 µm to 10 µm. The content of the filler is 0.01 part by mass to 200 parts by mass with respect to 100 parts by mass of the polymer. According to the present invention, foaming and a decrease of the accuracy of a three-dimensional object can be suppressed even when the soluble material for three-dimensional modeling is used in manufacture of the three-dimensional object with a 3D printer after being exposed to high humidity.