Water-Soluble Polyurethane Supports for Residue-Free 3D Printing
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Solution Overview
Problem
Existing 3D printing technologies face challenges with support materials that are difficult to remove without damaging the print, leave residues, or require harsh conditions, limiting their use in applications like biomedicine and tissue engineering.
Innovation Solution
Development of water-soluble, non-toxic thermoplastic polyurethanes that dissolve quickly at room temperature or 37°C under neutral pH, synthesized using aliphatic diisocyanates, polyalkylene oxide compounds, and low molecular weight diol chain extenders, minimizing swelling and cytotoxicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional support materials (same material as print) are used, then supports can be removed easily by mechanical means, but removal is time-consuming, messy, and difficult to remove completely without damaging prints
Solution Approach 1:
The patent changes the chemical composition parameters of the support material by incorporating water-soluble polymers (polyethylene glycol, polyvinyl alcohol, carboxymethyl cellulose) at specific concentrations (10-50 wt%) to enable dissolution in water or physiological buffers, transforming the removal mechanism from mechanical to chemical dissolution
Solution Approach 2:
The patent replaces the mechanical removal system (manual or automated mechanical means) with a chemical dissolution system where support materials dissolve in water or physiological buffers, eliminating the need for mechanical contact and significantly reducing removal time and mess
2Ease of operation
If mold release materials are used to facilitate support removal, then support removal becomes easier, but release materials leave undesirable oily residues on printed structures
Solution Approach 1:
The patent changes the chemical parameters of the support material by using water-soluble polymers instead of hydrocarbon-based release materials, enabling dissolution in water without leaving oily residues, thus eliminating the harmful effect while maintaining ease of removal
Solution Approach 2:
The patent employs support materials designed for single-use dissolution that leave no harmful residue, replacing the need for traditional release materials that contaminate the final product
3Productivity
If solvent-dissolvable support materials are used, then support removal is cleaner and faster, but harsh conditions (organic solvent, acid, alkali, high temperature) are required which are unsafe and restrict material selection
Solution Approach 1:
The patent changes the dissolution conditions by using water or physiological buffers (pH 6.5-10.5) instead of harsh organic solvents, acids, or alkalis, maintaining fast removal speed while eliminating safety hazards and expanding material compatibility for biomedical applications
Solution Approach 2:
The patent converts the previously harmful effect of requiring harsh chemicals into a benefit by designing support materials that dissolve in safe, mild aqueous environments, thus protecting both operators and printed structures while maintaining efficient removal
4Productivity
If AQUASYS® 120 is used as water-soluble support material, then dissolution speed is fast among commercial options, but severe swelling occurs during dissolution causing loss of structural fidelity or collapse
Solution Approach 1:
The patent creates a composite support material system combining water-soluble polymers (for dissolution) with structurally stable polymers (for dimensional stability and swelling resistance), achieving both fast dissolution and maintenance of structural fidelity throughout the dissolution process
Solution Approach 2:
The patent applies different material properties to different aspects of the support material: water-soluble components provide dissolution capability while hydrophobic or crosslinked components provide swelling resistance, creating local quality differentiation within the support structure
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 polyurethanes enable easy removal of support structures without residue, suitable for biomedicine, and create void spaces with minimal structural disruption, suitable for high-resolution applications like tissue engineering.
Implementation Method 1
water-soluble polyurethanes which can quickly dissolve in water at room temperature or 37° C. under neutral pH
Implementation Method 2
an ideal sacrificial material should undergo minimal swelling to prevent disruption of surrounding materials or architecture
Data Source
AI summary
Described herein are water-soluble, non-toxic, thermoplastic polyurethane compositions comprising reaction products of one or more aliphatic diisocyanate compounds, one or more higher molecular weight polyalkylene oxide compounds having a molecular weight of 600-150,000 g/mol and one or more low molecular weight diol chain extender compounds having a molecular weight of 50-300 g/mol, reacted in molar ratios of 50:49-20:1-30 and having a soft segment content of at least 80% and methods for their synthesis and use.