Sulfonated Thermoplastic Copolymer Support for Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing systems face challenges in quickly and efficiently removing support structures without the need for special tools or chemical solutions, which prolongs post-processing time and generates unwanted effluents.

Innovation Solution

A water-dispersible sulfonated thermoplastic copolymer is developed, which can be used as a support material in additive manufacturing. This copolymer is formulated to have a high glass transition temperature, excellent adhesion to part materials, and thermal stability, allowing it to be easily dissolved in tap water without the need for alkaline solutions or extended heating, facilitating rapid removal of support structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If traditional support materials are used in additive manufacturing, then support structures can be removed using chemical baths, but the process requires extended time and special chemical solutions

Engineering Contradiction:

Improvepost-processing timeVSAvoidchemical bath requirements

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The support material's chemical composition is changed by incorporating water-soluble polymers (such as polyacrylic acid, polyacrylamide, or carboxymethyl cellulose) that dissolve in neutral water at ambient temperature, eliminating the need for alkaline chemical baths and extended heating times

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The support material is designed as a disposable, biodegradable component that can be easily removed and discarded after serving its support function, replacing durable but chemically complex support materials with a single-use water-soluble alternative

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If conventional support materials are used, then structural support is provided during printing, but removal requires alkaline solutions and extended heating

Engineering Contradiction:

Improvesupport removal processVSAvoidheating temperature

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The material's thermal and chemical properties are modified by selecting polymers with low glass transition temperatures and high water solubility, allowing removal at ambient temperature without heating or chemical additives

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The chemical dissolution process replaces complex thermal and chemical treatment systems, using simple ambient temperature water to achieve support removal without heating equipment or chemical handling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of time

If water-soluble support materials are used, then quick removal is achieved, but adhesion to part materials may be compromised

Engineering Contradiction:

Improvesupport removal timeVSAvoidadhesion strength

Core Design Contradiction:

Loss of timeVSStrength

Solution Approach 1:

The support material uses composite formulations combining water-soluble polymers with adhesion promoters such as silane-modified polymers or polymer brushes that provide strong bonding to part materials while maintaining water solubility for easy removal

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different regions of the support material have differentiated properties: the bulk material remains water-soluble for easy removal, while surface-modified regions contain adhesion promoters that bond strongly to part materials during the printing process

Inventive Principle:

Principle #3Local quality

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 water-dispersible sulfonated thermoplastic copolymer enables quick and efficient removal of support structures in additive manufacturing, reducing post-processing time and eliminating the need for chemical baths, while maintaining the integrity of printed parts.

Implementation Method 1

a water-dispersible sulfonated thermoplastic copolymer... dispersible in tap water at ambient temperature without the aid of any other solubility or dispersibility adjuvant

Methodology Applied

Scientific EffectWater dispersibility: Solvation

Implementation Method 2

a glass transition temperature of at least approximately 45 C

Methodology Applied

Scientific EffectGlass transition:

Data Source

PatentUS20240191087A1Water dispersible sulfonated thermoplastic copolymer for use in additive manufacturing

Publication Date: 2024.06.13 STRATASYS INC

AI summary

A sulfonated water-dispersible thermoplastic copolymer material for use as a support material in an additive manufacturing process is made by a method comprising providing a selected thermoplastic copolymer having an acid or an anhydride group; esterifying the acid group of the selected thermoplastic copolymer with a hydroxyl-functionalized sulfonate salt, or amidizing the acid group of the selected thermoplastic copolymer with an amine sulfonate salt, or imidizing the anhydride group of the selected thermoplastic copolymer with an amine sulfonate salt. The esterification, the amidization or the imidization results in a sulfonated water thermoplastic dispersible copolymer having a glass transition temperature suitable to provide an effective support during the additive manufacturing process and wherein the sulfonated water-dispersible thermoplastic copolymer will disperse in tap water in less than 1 hour.