Water-Soluble Photocurable Resin for 3D Print Support Removal
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Solution Overview
Problem
Conventional photochemical 3D fabrication methods using photocurable resin compositions face challenges in producing multi-colored or multi-property 3D objects with reduced material usage and equipment scale, while also experiencing distortion issues due to self-weight and heat effects, necessitating the development of effective support regions that can be easily removed without mechanical means.
Innovation Solution
A photocurable resin composition for support regions comprising N-hydroxyalkyl (meth)acrylamide, (meth)acryloyl morpholine, (meth)acrylate compounds, and polyhydroxy compounds, which allows for low viscosity, excellent photocuring performance, and high water solubility, enabling the formation of support regions that can be readily removed with a weak external force like a water jet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional photochemical fabrication method using fabrication tank is used, then high dimensional accuracy is achieved, but large scale equipment and large amount of photocurable resin are required
Solution Approach 1:
The patent replaces the conventional fabrication tank system with an inkjet printing system that deposits photocurable resin directly onto the build platform. This substitution of the mechanical delivery system allows for precise material placement without requiring large-scale equipment, while maintaining dimensional accuracy through digital control of droplet placement patterns
Solution Approach 2:
The patent changes the method of resin delivery from bulk liquid in a tank to controlled droplet deposition. By adjusting parameters such as droplet size, deposition pattern, and layer thickness, the system achieves high dimensional accuracy with minimal material usage and small-scale equipment
2Strength
If support regions are formed using same material as main body, then structural support is provided, but mechanical removal is required which affects accuracy and appearance
Solution Approach 1:
The patent applies different material properties to different regions: the main body uses photocurable resin that cures to a solid, durable material, while the support regions use a water-soluble photocurable resin that cures during fabrication but can be easily removed afterward. This local differentiation of material properties allows mechanical support during printing without compromising final accuracy or appearance
Solution Approach 2:
The support regions are designed as temporary structures that are discarded after serving their support function. The water-soluble resin allows for easy removal by dissolution, eliminating the need for mechanical removal methods that could damage the main body's accuracy and appearance
3Ease of operation
If water-soluble photocurable resin is used for support regions, then easy removal is achieved, but photocuring performance and supporting strength are insufficient
Solution Approach 1:
The patent uses a composite photocurable resin formulation for support regions that combines water-soluble polymers with photopolymerizable components. This composite material provides both the required supporting strength during fabrication and the water-solubility for easy removal afterward, resolving the contradiction between strength and ease of removal
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 composition ensures smooth discharge from nozzles without clogging, provides sufficient support during fabrication, and allows for easy removal of support regions from the main body, maintaining the accuracy and appearance of the 3D object without mechanical intervention.
Implementation Method 1
comprises from 0.1 to 5 mass % of a photopolymerization initiator and from 3 to 30 mass % of a (meth)acrylate compound containing at least one (meth)acryloyloxy group
Data Source
AI summary
A photocurable resin composition for support regions for use in photochemical fabrication by an inkjet method, which has low viscosity and outstanding photocurability, and where the support regions, formed by the photocuring, have good supporting performance and, following the end of the photochemical fabrication, can readily be removed from the main body by dissolving in water and/or by a weak external force such as a water jet. The photocurable resin composition for support regions for use in photochemical 3D fabrication by the inkjet method contains, based on the total mass of photocurable resin composition, from 2 to 20 mass % of N-hydroxyalkyl (meth) acrylamide, from 2 to 20 mass % of (meth) acryloyl morpholine, from 3 to 30 mass % of (meth) acrylate compound having at least one (meth) acryloyloxy group, from 40 to 90 mass % of polyhydroxy compound containing two or more hydroxyl groups, and from 0.1 to 5 mass % of a photo-radical polymerization initiator.