UV Fusing Agent Composition for Precise 3D Printing
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Solution Overview
Problem
Existing 3D printing methods using infrared and visible radiation face issues with selectivity, leading to inaccurate part shapes and dark-colored prints due to non-patterned material absorption, and narrow-band emission sources like UV LEDs are not effectively utilized.
Innovation Solution
A UV light fusing agent formulated with B vitamins or derivatives, soluble in water, is used to absorb UV radiation and convert it to thermal energy for precise coalescence, avoiding the need for adhesives and producing lighter-colored 3D objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If infrared and visible radiation are used for 3D printing, then material coalescence can be achieved, but selectivity is poor leading to inaccurate part shapes and dark-colored prints
Solution Approach 1:
The patent applies local quality by using UV-absorbing agents that are selectively applied only to specific regions of the build material layer. This creates localized UV absorption zones that precisely control where coalescence occurs, rather than uniform heating across the entire layer. The selective regional application ensures that only patterned areas absorb UV energy and undergo phase change, achieving accurate part shapes while preventing unwanted darkening of non-patterned regions.
Solution Approach 2:
The patent addresses color changes by using UV-absorbing agents with specific optical properties that do not cause darkening of the final part. Unlike infrared absorbers that cause broad-spectrum heating and darkening, the UV-absorbing agents operate at specific wavelengths and can be formulated to maintain the original color characteristics of the build material, producing lighter-colored prints as desired.
2Temperature
If broad-spectrum radiation sources are used, then material heating is effective, but selectivity and precision are reduced
Solution Approach 1:
The patent applies parameter changes by transitioning from broad-spectrum infrared/visible radiation to narrow-band UV radiation at specific wavelengths (300-405 nm). This wavelength parameter change enables precise control over which materials absorb energy, as UV-absorbing agents are selectively applied to patterned regions. The narrow-band UV source provides effective heating only where agents are present, maintaining temperature efficiency while dramatically improving pattern definition accuracy.
3Manufacturing precision
If UV LEDs are used as narrow-band emission sources, then selectivity improves, but current technology does not effectively utilize them
Solution Approach 1:
The patent introduces UV-absorbing agents as intermediary substances that bridge the UV LED light source and the build material. These agents act as mediators by absorbing UV radiation at specific wavelengths and converting it to thermal energy that drives coalescence. This intermediary approach enables effective utilization of UV LEDs, converting their narrow-band emission into controlled heating while maintaining the selectivity and precision advantages of UV radiation.
Solution Approach 2:
The patent replaces traditional mechanical or broad-spectrum thermal heating systems with a photonic system using UV LEDs and UV-absorbing agents. This substitution transitions from non-selective thermal fields to selective photonic fields, where energy delivery is controlled by light absorption characteristics rather than thermal conduction. The result is both improved precision through selective energy deposition and maintained productivity through efficient UV-to-thermal conversion by the absorbing agents.
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 UV light fusing agent enables precise and efficient 3D printing with controlled voxel application, producing accurate shapes and lighter-colored objects suitable for various applications, including food packaging and biomedical uses.
Implementation Method 1
an energy absorber in the fusing agent absorbs the radiation and converts the absorbed radiation to thermal energy
Implementation Method 2
The energy absorber in the fusing agent absorbs the radiation and converts the absorbed radiation to thermal energy, which in turn fuses/coalesces the polymeric build material
Implementation Method 3
the patterned region (which, in some instances, is less than the entire layer) of the polymeric build material is fused/coalesced and hardened
Implementation Method 4
Fusing/coalescing may involve at least partial thermal merging, melting, binding, and/or some other mechanism that coalesces the polymeric build material
Implementation Method 5
at least partial thermal merging, melting, binding
Data Source
AI summary
An example of a kit for three-dimensional (3D) printing includes an ultraviolet (UV) light fusing agent. The ultraviolet (UV) light fusing agent includes an aqueous vehicle and a B vitamin or a B vitamin derivative present in an amount that dissolves in the aqueous vehicle. The aqueous vehicle includes a co-solvent, a surfactant, and water. The B vitamin or the B vitamin derivative has absorption at wavelengths ranging from about 340 nm to about 415 nm.