3D Printing Support Material Formulation for Fast Alkaline Dissolution
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Solution Overview
Problem
Current support materials in 3D inkjet printing are difficult to remove efficiently, often requiring hazardous chemicals, manual labor, and long dissolution times, which can damage the printed object and are unsuitable for office environments.
Innovation Solution
A novel support material formulation comprising a non-curable water-miscible polymer, a first curable material, and a second curable material that interferes with intermolecular interactions, allowing for rapid dissolution in an alkaline solution without compromising mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support material is designed to have sufficient mechanical strength for holding model material, then structural support capability is improved, but dissolution time increases and removal becomes more difficult
Solution Approach 1:
The patent changes the chemical composition parameters of the support material by incorporating hydrophilic polymers (polyvinyl alcohol, polyacrylonitrile, carboxymethyl cellulose) with specific molecular weights and degrees of hydrolysis. These parameter changes enable the material to have sufficient mechanical strength during printing while allowing rapid dissolution in aqueous solutions, reducing dissolution time from hours to minutes.
Solution Approach 2:
The support material is designed as a composite formulation containing multiple components: hydrophilic polymers for strength and solubility, surfactants for wetting and dissolution enhancement, and optional additives for specific properties. This composite approach allows simultaneous achievement of mechanical strength and rapid removability that single materials cannot provide.
2Loss of time
If support material is designed for rapid dissolution to reduce removal time, then dissolution speed is improved, but mechanical strength decreases and support capability is compromised
Solution Approach 1:
The patent optimizes the degree of hydrolysis of polyvinyl alcohol (87-99%) and molecular weight parameters to achieve the optimal balance between strength and solubility. By precisely controlling these parameters, the support material dissolves rapidly in aqueous solutions while maintaining sufficient mechanical strength during the printing process.
Solution Approach 2:
Surfactants are introduced as intermediary substances that enhance the wetting and dissolution of the support material. These surfactants facilitate faster dissolution by improving aqueous solution penetration and interaction with the polymer matrix, enabling rapid removal while preserving mechanical strength.
3Ease of manufacture
If conventional support materials are used, then ease of jetting is maintained, but removal requires hazardous chemicals and manual labor
Solution Approach 1:
The patent converts the previously harmful characteristic of support material permanence into a beneficial property by designing hydrophilic polymers that rapidly dissolve in aqueous solutions. This eliminates the need for hazardous chemical solvents and manual removal processes, allowing simple water-based removal while maintaining jetting capability through appropriate viscosity control.
Solution Approach 2:
The patent replaces mechanical removal methods (manual labor, tools, water-jet impact) with a chemical dissolution process using benign aqueous solutions. The hydrophilic polymer formulation enables automatic dissolution and detachment of support material, eliminating labor-intensive mechanical removal operations.
4Ease of manufacture
If support material viscosity is reduced for easy jetting, then dispensing capability is improved, but mechanical strength decreases and geometric accuracy deteriorates
Solution Approach 1:
The patent controls the viscosity parameter of the support material by selecting polymers with appropriate molecular weights and concentrations. The formulation achieves low enough viscosity for easy jetting (adequate flow through nozzles) while maintaining sufficient viscosity for geometric accuracy (preventing spreading and maintaining defined shapes during deposition).
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 formulation enables support material to dissolve quickly in alkaline solutions, reducing dissolution time by at least two-fold while maintaining mechanical strength, suitable for 3D inkjet printing applications.
Implementation Method 1
at least one second water-miscible curable material which is capable of interfering with intermolecular interactions between polymeric chains formed upon exposing the first water-miscible material to curing energy
Implementation Method 2
The formulation enables support material to dissolve quickly in alkaline solutions
Implementation Method 3
dissolve quickly in alkaline solutions
Data Source
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Figure 3
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AI summary
Novel support material formulations, characterized as providing a cured support material with improved dissolution rate, while maintaining sufficient mechanical strength, are disclosed. The formulations comprise a water-miscible non-curable polymer, a first water-miscible, curable material and a second, water-miscible material that is selected capable of interfering with intermolecular interactions between polymeric chains formed upon exposing the first water-miscible material to curing energy. Methods of fabricating a three-dimensional object, and a three-dimensional object fabricated thereby are also disclosed.