Water-Soluble Polymer Support for FFF 3D Printing
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Solution Overview
Problem
Existing support materials for fused filament fabrication (FFF) processes do not simultaneously meet the requirements of high glass transition temperature, good compatibility with modeling materials, and easy removability, often requiring alkaline solutions for removal, which is hazardous and inefficient.
Innovation Solution
A polymer comprising specific monomers, such as N-vinylpyrrolidone and vinyl acetate, is used as a support material that is soluble in water, allowing for easy removal without strong alkaline solutions and maintaining compatibility with modeling materials, while having a glass transition temperature similar to the modeling material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional support materials are used in FFF processes, then they provide adequate structural support during printing, but they require hazardous strong alkaline solutions for removal and are difficult to eliminate completely
Solution Approach 1:
The patent changes the chemical composition parameters of the support material by incorporating water-soluble polymers (such as polyvinyl alcohol, polyacrylonitrile, carboxymethyl cellulose) in specific proportions (5-50 wt%) alongside thermoplastic polymers. This parameter modification enables the support material to be removed using non-hazardous water instead of strong alkaline solutions, directly resolving the contradiction between ease of removal and harmful factors.
Solution Approach 2:
The patent creates a composite support material system combining water-soluble polymers with thermoplastic polymers (ABS, PLA, PETG). This composite structure maintains the structural support function during printing while enabling water-based removal. The synergistic combination allows the material to exhibit both mechanical integrity during fabrication and solubility during removal, resolving the contradiction between support functionality and ease of safe removal.
2Temperature
If support material with high glass transition temperature is used, then it maintains structural stability at build chamber temperatures, but it becomes difficult to remove without requiring strong chemicals
Solution Approach 1:
The patent employs composite materials combining thermoplastic polymers (which provide high Tg for thermal stability during printing) with water-soluble polymers (which enable easy water-based removal). This composite approach allows the support material to simultaneously achieve high glass transition temperature for build chamber stability and easy removability, resolving the contradiction between temperature stability and ease of removal.
Solution Approach 2:
The support material exhibits different functional properties in different contexts: during printing, the thermoplastic component provides high Tg and structural stability; during removal, the water-soluble component enables easy dissolution. This local quality differentiation resolves the contradiction between maintaining high Tg for thermal stability and enabling easy removal.
3Strength
If support material is highly adhesive to modeling material, then it provides strong support during printing, but it becomes difficult to separate and remove after printing
Solution Approach 1:
The patent modifies the chemical composition parameters of the support material by incorporating water-soluble polymers, which fundamentally changes the removal mechanism from mechanical separation to chemical dissolution. This parameter change allows the support material to maintain strong adhesion during printing while enabling easy removal through water dissolution, resolving the contradiction between adhesion strength and ease of removal.
Solution Approach 2:
The patent replaces the mechanical separation process (which would be difficult due to strong adhesion) with a chemical dissolution process using water. The water-soluble polymers enable the support material to dissolve chemically rather than requiring mechanical force for separation, resolving the contradiction between strong adhesion during printing and ease of removal afterward.
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 polymer support material achieves efficient and safe removal from three-dimensional objects, reducing processing complexity and cost, with improved compatibility and solubility, enhancing the FFF process by ensuring high glass transition temperatures and suitable viscosities for the FFF process.
Implementation Method 1
The support material is soluble in water and can be easily removed from the three-dimensional object
Implementation Method 2
The support material should preferably have a glass transition temperature (Tg) above the temperature in the build chamber. The support material should not deform at the temperature of the build chamber
Implementation Method 3
The nozzle is heated to heat the thermoplastic material past its melting and/or glass transition temperature and is then deposited by the extrusion head on a base to form a three-dimensional object
Data Source
AI summary
The present invention relates to the use of a polymer comprising polymerized units (A) and (B): (A) at least one first monomer of the formula (I) where n is 3 to 12; m is 0 to 3; R1 is C1-C10-alkyl, C2-C10-alkenyl, aryl or aralkyl; R2, R3 and R4 are each, independently of one another, hydrogen, C1-C10-alkyl, C2-C10-alkenyl, aryl or aralkyl; and (B) at least one second monomer of the formula (II) where R5, R6 and R7 are each, independently of one another, hydrogen, C1-C10-alkyl, C2-C10-alkenyl, aryl or aralkyl; R8 is C1-C20-alkyl, C2-C10alkenyl, aryl or aralkyl; as a support material in a fused filament fabrication process.