Vat Photopolymerization Using Multi-Wavelength Selective Polymerization
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Solution Overview
Problem
Vat photopolymerization methods in 3D printing are limited by the need for manual removal of support structures, which is time-consuming and labor-intensive, especially when using vertical stacks, and lack the ability to create multi-material objects with soluble components or multi-color features.
Innovation Solution
A process using a multi-wavelength light source to selectively polymerize different materials within a resin, allowing for the creation of 3D objects with multiple material regions, including soluble and non-soluble segments, and multi-color features, by irradiating the resin with distinct wavelengths to activate different polymerization initiators and achieve distinct polymerization mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual removal of support structures is used, then support structures can be removed, but the process is time-consuming and labor-intensive
Solution Approach 1:
The patent changes the chemical parameter of the support structure material by using a polymerizable composition with specific functional groups that react with dissolution bath components. This transforms the support structures from non-soluble to soluble, enabling automated chemical dissolution instead of manual removal, thereby reducing time and labor while maintaining manufacturability
Solution Approach 2:
The patent replaces the mechanical process of manual support structure removal with a chemical dissolution process. The support structures are designed to dissolve chemically in a dissolution bath, substituting mechanical labor with automated chemical treatment, which significantly reduces time and labor requirements
2Adaptability or versatility
If single material formulation is used, then manufacturing process is simple, but multi-material and multi-color objects cannot be created
Solution Approach 1:
The patent segments the polymerizable composition into multiple distinct material formulations, each with unique properties such as different functional groups, photoinitiators, or pigments. This segmentation enables the creation of multi-material objects with different characteristics in different regions, while each segment remains a manageable formulation that can be processed independently
Solution Approach 2:
The patent creates a universal polymerizable composition system that can produce multiple material types within a single formulation framework. By using a common base structure with variable functional components (photoinitiators, monomers, pigments), the system achieves multi-functionality, allowing one composition type to generate diverse materials with different properties without requiring entirely separate formulation systems
3Productivity
If support structures are needed for vertical stacks, then throughput increases, but manual separation becomes more time-intensive
Solution Approach 1:
The patent changes the solubility parameter of the support structure material by incorporating specific functional groups that enable chemical dissolution. This allows support structures in vertical stacks to be automatically removed through chemical treatment rather than manual separation, maintaining high productivity from vertical stacking while eliminating the time-intensive manual separation step
Solution Approach 2:
The patent replaces mechanical manual separation of support structures from vertically stacked parts with automated chemical dissolution. The support structures are designed to dissolve in a dissolution bath, substituting labor-intensive mechanical separation with automated chemical processing, thereby maintaining high throughput while reducing separation time
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
Enables efficient and automated removal of support structures and the creation of complex multi-material and multi-color 3D objects, improving manufacturing efficiency and enabling the use of vat photopolymerization for production purposes.
Implementation Method 1
Vat photopolymerization is a form of 3D printing technology that takes advantage of photopolymerization processes, to solidify a photo-reactive resin
Data Source
AI summary
A vat photopolymerization process comprises irradiating a resin comprising two or more different types of polymerizable materials and two or more different types of light-sensitive materials, at least two of said two or more light-sensitive materials are selected from radical and ionic initiators, wherein each of the two or more different types of polymerizable materials is polymerized into a different polymeric material by a different initiator of the at least two initiators, wherein one or more of the two or more different types of polymerizable materials is polymerized into one or more soluble polymeric materials that are each partially or fully soluble in a fluid selected from a solvent and a solution, said fluid not present in the resin and in which each of the other polymeric materials are insoluble; wherein said irradiating comprising directing a multiwavelength device or a plurality of light sources generating radiation of different wavelengths in a direction of the resin to initiate or induce selective polymerization of each of the two or more different types of polymerizable materials in different regions of the resin to yield the 3D object; and treating the object in the fluid to cause dissolution of the one or more soluble polymeric materials in the solvent or the solution, maintaining intact each of the other polymeric materials present in the object.