Transparent Curable Formulation for UV LED Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing techniques using UV LED light sources face limitations due to photoinitiators that absorb shorter wavelengths, leading to reduced process quality and mechanical stability issues in 3D inkjet printing, particularly with the use of materials like acrylics, which result in increased yellow hue and reduced shelf-life.
Innovation Solution
A curable formulation comprising 85-95% curable materials, including a phosphine oxide-type photoinitiator activated at wavelengths higher than 380 nm, and a thioether with hydrocarbon chains, which provides a transparent material with light transmittance greater than 70% and minimal yellow hue, avoiding sulfur-containing thiols and using a silicon-based surface active agent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional photoinitiators absorbing shorter wavelengths are used with UV LED curing, then the curing process can be initiated, but the material exhibits increased yellow hue and reduced shelf-life
Solution Approach 1:
The patent changes the wavelength parameter of photoinitiator absorption to match UV LED output (higher than 380 nm), which fundamentally alters the interaction between curing light and photoinitiator, eliminating yellow hue while maintaining shelf-life
Solution Approach 2:
The patent employs a specific photoinitiator formulation that is optimized for single-use in UV LED curing processes, achieving effective curing without long-term degradation issues that plague conventional photoinitiators
2Use of energy by moving object
If UV LED light sources are used for curing, then energy efficiency is improved, but process quality and mechanical stability deteriorate due to photoinitiator limitations
Solution Approach 1:
The patent adjusts photoinitiator wavelength absorption parameters to align with UV LED emission spectrum, ensuring efficient energy utilization while achieving high process quality and mechanical stability in the cured material
3Strength
If sulfur-containing thiols are used in the formulation, then certain material properties are achieved, but mechanical stability and shelf-life are reduced
Solution Approach 1:
The patent removes sulfur-containing thiol compounds from the formulation entirely, replacing them with alternative compounds that do not compromise mechanical stability or shelf-life, thereby eliminating the harmful effects of sulfur contamination
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 achieves high light transmittance and reduced yellow hue, enhancing the mechanical stability and shelf-life of 3D printed objects while being compatible with UV LED curing, overcoming previous limitations in UV LED-based additive manufacturing.
Implementation Method 1
A curable formulation comprising 85-95% curable materials, including a phosphine oxide-type photoinitiator activated at wavelengths higher than 380 nm
Implementation Method 2
which provides a transparent material with light transmittance greater than 70% and minimal yellow hue
Data Source
AI summary
Curable formulations which are usable in additive manufacturing of three-dimensional objects using a transparent material, and which can be advantageously usable in additive manufacturing systems that utilize a LED curing source are provided. Additive manufacturing processes using same and objects made thereby are also provided.