Solution-Based Additive Manufacturing Ink for Polymer Phase Change
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Solution Overview
Problem
Current additive manufacturing techniques, such as 3D printing, are limited by the need for specific polymers with moderate melting points or photoreactivity, excluding a wide range of advanced functional polymers from being processed.
Innovation Solution
A solution-based additive manufacturing method using a ternary ink comprising a polymer, a volatile solvent compound, and a nonsolvent compound, where the volatile solvent evaporates to drive a phase change from a liquid ink phase to a solid extruded phase, allowing for the processing of any desired polymer without limitations based on melting points or photoreactivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional additive manufacturing methods are used, then specific polymers with moderate melting points or photoreactivity can be processed, but a wide range of advanced functional polymers are excluded from being used
Solution Approach 1:
The invention changes the processing parameters by using solution-based extrusion instead of melt-based or photopolymerization methods. The ink composition parameters (polymer concentration, solvent type, nonsolvent ratio) are adjusted to enable phase change at extrusion, allowing any polymer that can be dissolved to be processed, thus expanding polymer selection while maintaining manufacturability
Solution Approach 2:
The invention utilizes phase transition as the core mechanism for material deposition. By controlling the phase change from liquid ink to solid polymer through solvent evaporation and nonsolvent addition, the system can process any polymer that forms a soluble ink, eliminating the need for photoreactivity or moderate melting points and significantly expanding the range of usable polymers
2Manufacturing precision
If a volatile solvent compound is evaporated to drive phase change, then the ink transitions from liquid to solid phase, but control over evaporation rate and phase change timing is required
Solution Approach 1:
The invention introduces a nonsolvent compound as an intermediary substance that mediates the phase change process. The nonsolvent triggers rapid phase separation and solidification upon contact with the extruded ink, providing precise control over phase change timing and location without requiring complex evaporation control systems. This intermediary mechanism enables reliable solidification while maintaining system simplicity
Solution Approach 2:
The volatile solvent compound naturally evaporates at ambient or controlled conditions, providing self-regulating evaporation control. The system leverages the inherent volatility properties of the solvent to achieve phase change without requiring active heating or cooling systems, thereby maintaining manufacturing precision while minimizing device 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
Enables the use of a broad range of polymers in additive manufacturing, extending the design space and capabilities of polymer-based devices and structures by allowing phase change from a liquid to a solid phase during extrusion.
Implementation Method 1
the volatile solvent evaporates to drive a phase change from a liquid ink phase to a solid extruded phase
Implementation Method 2
the evaporating causes a phase change in the ink from a liquid ink phase to a solid extruded phase
Data Source
AI summary
Disclosed herein are solution-based additive manufacturing inks comprising a polymer, a volatile solvent compound, and a nonsolvent compound. With current additive manufacturing techniques, a wide range of functionally innovative polymers are left without the ability to be used in additive manufacturing. Improved additive manufacturing techniques to process advanced functional polymers are desirable. The disclosed ink is operable to render any chosen polymer useable in additive manufacturing methods. The composition of the disclosed ink allows for a phase inversion to occur to transition the ink from a liquid ink to a solid manufactured structure. Also disclosed herein are devices for additive manufacturing of the ink and methods for making the same.