UV-Cured 3D Printing Material for High-Strength Parts
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Solution Overview
Problem
Current 3D printing technologies face challenges with the physical and chemical properties of materials, particularly thermoplastic resins, which result in slow modeling speed, poor mechanical properties, oxidative decomposition, and the release of toxic gases, limiting their application and efficiency.
Innovation Solution
A composition comprising a photosensitive monomer, micro-nano powder, crosslinking agent, toughening agent, and pigment, combined with a process that uses UV radiation for crosslinking, eliminating the need for high-temperature melting and resulting in a high-strength, environmentally friendly 3D printing material with improved production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic resins are used for 3D printing with high temperature melting, then the material can be shaped and deposited layer by layer, but the modeling speed is slow and toxic gases are released
Solution Approach 1:
The patent changes the fundamental parameter of material processing from thermal melting to photochemical polymerization. The composition uses photosensitive monomers that solidify rapidly under UV irradiation, eliminating the slow high-temperature melting process while maintaining shaping capability and avoiding toxic gas emissions.
Solution Approach 2:
The patent replaces the thermal-mechanical system (heating and melting) with a photochemical system (UV irradiation and polymerization). This substitution enables rapid solidification and shaping without the need for high temperature processing, thereby increasing modeling speed and eliminating harmful emissions.
2Ease of manufacture
If thermoplastic resins are used for 3D printing, then the material can be deposited layer by layer, but the mechanical properties such as strength and toughness are poor
Solution Approach 1:
The patent employs a composite material system combining photosensitive monomers, photoinitiators, and various functional additives (crosslinking agents, toughening agents, fillers). This composite approach enables the final printed product to achieve superior mechanical properties including enhanced strength, toughness, and heat resistance while maintaining the layer-by-layer deposition capability.
Solution Approach 2:
The patent transforms the material state from thermoplastic melt to crosslinked polymer network through photochemical polymerization. This parameter change in the chemical structure and bonding nature of the material results in significantly improved mechanical properties while preserving the additive manufacturing processability.
3Ease of manufacture
If thermoplastic resins are melted at high temperature, then the material can be solidified to form product, but oxidative decomposition occurs and toxic gases are released
Solution Approach 1:
The patent replaces the thermal processing system with a photochemical system. Instead of heating and melting thermoplastic resins which causes oxidative decomposition and toxic gas release, the invention uses UV irradiation to initiate polymerization of photosensitive monomers, achieving solidification without high temperature and eliminating harmful emissions.
Solution Approach 2:
The patent creates a chemically inert processing environment by using photochemical polymerization instead of thermal melting. This alternative mechanism avoids oxidation and decomposition reactions that occur at high temperatures, effectively eliminating toxic gas generation while maintaining the solidification function.
4Ease of manufacture
If thermoplastic materials are used for 3D printing, then the product can be formed, but the heat resistance and rigidity of the printed product are poor
Solution Approach 1:
The patent uses a composite formulation including photosensitive monomers, crosslinking agents, and functional fillers that collectively provide enhanced heat resistance and rigidity. The crosslinked polymer network structure formed through UV polymerization inherently offers superior thermal stability compared to thermoplastic materials, while the deposition process remains straightforward.
Solution Approach 2:
The patent changes the chemical structure parameter from linear thermoplastic chains to crosslinked polymer networks. This structural transformation fundamentally improves the thermal properties and rigidity of the printed product while maintaining the ease of manufacturing through photochemical solidification.
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 solution enables rapid solidification and shaping under UV irradiation, reducing toxic gas emissions, enhancing mechanical properties, and allowing for the production of complex structures with improved heat resistance and dimensional stability, while being cost-effective and suitable for industrial production.
Implementation Method 1
comprises a photosensitive monomer, micro-nano powder, crosslinking agent, toughening agent, and pigment, combined with a process that uses UV radiation for crosslinking
Data Source
AI summary
The present invention provides a composition for 3D printing, a process for preparing the same and an article thereof. By the solidifying method of UV irradiation, 3D printing is implemented. During said implementation, there is no need of high temperature heating, thus energy consumption is reduced, and there is no need for special solvent, thus harm to the environment is reduced. Meanwhile, the present invention uses micro-nano powder as the main material and polymer resin as adhesive, and at the same time, adds irradiation sensitizer. After electron beam irradiation, the polymer resin forms three-dimensional crosslinked network, thereby the strength, heat resistance and chemical resistance are improved after resin adhesion. Additionally, the present invention, by the addition of UV crosslinking agent, and by UV irradiation, cross-links the unsaturated resin after extrusion in 3D printing to form three-dimensional network structure, thus greatly improves the heat resistance, chemical resistance and mechanical strength of the shaping material, and makes the unsaturated resin have broader application prospects in 3D printing material.