Thiol-ene 3D Printing Inks for High Resolution and Toughness
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Solution Overview
Problem
Existing 3D printing inks often struggle to achieve a balance between high printing resolution and mechanical toughness, resulting in printed articles that are either rigid and brittle or flexible but easily broken.
Innovation Solution
The development of inks comprising a thiol monomer and an ethylenically unsaturated monomer, which react in a thiol-ene reaction to form a polymer network, along with an additional (meth)acrylate monomer that can form a separate polymer network, either interpenetrating or distinct, to enhance mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If (meth)acrylates are used as primary curable material in 3D printing inks, then high printing resolution is achieved, but the printed articles become rigid and brittle or flexible but easily broken
Solution Approach 1:
The patent applies composite materials by combining thiol monomers with ethylenically unsaturated monomers to create a hybrid polymer network. This composite approach allows the material to simultaneously achieve high printing resolution through the unsaturated monomer component and improved mechanical toughness through the thiol component, resolving the contradiction between manufacturing precision and strength.
Solution Approach 2:
The patent utilizes parameter changes by controlling the thiol-ene reaction through photoinitiation and thermal activation. By adjusting reaction parameters such as light exposure, temperature, and monomer ratios, the system achieves both high resolution printing and enhanced mechanical properties, transforming the material characteristics to satisfy both requirements.
2Ease of manufacture
If a single polymer network is formed, then the printing process is simple, but the mechanical properties are limited
Solution Approach 1:
The patent merges two polymerization mechanisms - thiol-ene reaction and (meth)acrylate polymerization - into a single ink formulation. This combining allows the formation of interpenetrating or combined polymer networks that enhance mechanical properties while maintaining relative printing process simplicity, as both reactions can be initiated through the same photoinitiator system.
Solution Approach 2:
The patent achieves multi-functionality by designing an ink system where a single photoinitiator can trigger both thiol-ene reaction and (meth)acrylate polymerization. This universal initiation mechanism allows the formation of complex polymer networks without requiring separate processing steps, thereby improving mechanical properties while keeping the manufacturing process relatively simple.
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
These inks enable the creation of 3D articles with high toughness and resolution, as well as improved mechanical properties, by forming interpenetrating polymer networks that provide enhanced strength and flexibility.
Implementation Method 1
The thiol monomer component and the ethylenically unsaturated monomer component can be chosen to react with one another in a so-called thiol-ene reaction
Implementation Method 2
the additional (meth)acrylate monomer component can be polymerized separately from the thiol and ene monomers of the ink
Implementation Method 3
a binder material or a laser, digital light processing (DLP) source, or other source of energy is used to selectively solidify or consolidate layers of the ink or build material
Data Source
AI summary
In one aspect, inks for use with a three-dimensional printing system are described herein. In some embodiments, an ink described herein comprises a thiol monomer component and an ene monomer component. Moreover, in some cases, an ink described herein further comprises an additional (meth)acrylate monomer component differing from the ene monomer component. In some such cases, the additional (meth)acrylate monomer component can be polymerized separately from the thiol and ene monomers of the ink.