Water-Soluble 3D Printing Support Material for Rapid Removal
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Solution Overview
Problem
Current 3D inkjet printing technologies face challenges in efficiently and safely removing support materials, which can be time-consuming, damage the object, and require hazardous chemicals or manual labor, especially for complex geometries and large parts.
Innovation Solution
A composition comprising a glycol polymer, a low molecular weight polar substance, and a surface active agent is used as a support material in 3D inkjet printing, allowing for quick and automatic removal by dissolution in water, with a balance of water solubility, melting temperature, and viscosity for efficient inkjet printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If phase change materials (wax) are used as support material and melted for removal, then support material can be removed in liquid state, but the temperature required for melting may cause deformation of the model structure
Solution Approach 1:
The patent changes the removal mechanism from thermal (melting wax) to chemical (dissolution in water). The support material is formulated with water-soluble polymers and salts that dissolve at room or slightly elevated temperatures, eliminating the need for high-temperature melting that would deform temperature-sensitive model materials.
Solution Approach 2:
The patent utilizes phase transition of water from liquid to vapor through heating during the dissolution process, enhancing the dissolution kinetics and removing support material efficiently without requiring the model itself to withstand high temperatures.
2Ease of operation
If soluble supporting materials are used for small parts, then support removal is simplified, but large masses of soluble material require lengthy dissolving time
Solution Approach 1:
The patent modifies the dissolution parameters by heating the water and adding salts to change the solvent properties. This dramatically accelerates the dissolution rate, reducing support removal time from hours to minutes regardless of support material mass, while maintaining ease of removal.
Solution Approach 2:
The patent introduces salts as intermediary substances that enhance water's dissolving capability. The salts interact with the polymer matrix of the support material, breaking down the structure more rapidly and facilitating faster removal of both small and large support constructions.
3Productivity
If mechanical impact methods are used for support material removal, then support can be removed physically, but the process is labor intensive and unsuited for small intricate parts
Solution Approach 1:
The patent replaces mechanical removal methods (impact, scraping) with chemical dissolution. The support material dissolves in heated saltwater solution, allowing automatic removal without manual labor or complex mechanical tools, making the process suitable for intricate geometries and reducing labor intensity.
4Productivity
If aggressive chemical solvents are used for support material dissolution, then support material can be dissolved effectively, but safety precautions and expensive waste disposal are required
Solution Approach 1:
The patent changes the chemical composition of the dissolution medium from aggressive organic solvents to aqueous salt solutions. By adjusting temperature and salt concentration, the dissolution effectiveness is maintained or improved while eliminating safety hazards and waste disposal issues associated with toxic chemicals.
Solution Approach 2:
The patent converts the typically problematic property of water (slow dissolution at room temperature) into a benefit by heating it and adding salts. This transforms water from an ineffective solvent into a powerful, safe, and environmentally friendly dissolving medium that outperforms aggressive chemicals.
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 enables rapid and environmentally safe removal of support materials, reducing processing time and minimizing risk to the object, while maintaining mechanical strength and preventing geometrical defects, suitable for both small and large intricate parts.
Implementation Method 1
the material composition is water soluble... comprising a glycol polymer and a low molecular weight polar substance
Implementation Method 2
the material composition further includes a surface active agent... the surface tension of the material composition is reduced to a level of 27-33 mN/m
Implementation Method 3
Both materials, i.e modeling material and supporting material might be initially liquid and are subsequently hardened to form the required layer shape
Data Source
AI summary
A material composition, which may be a support material, for three-dimensional (3D) inkjet printing is disclosed. The material composition may comprise a glycol polymer, a low molecular weight polar substance and a surface-active agent. The glycol polymer may be polyethylene glycol (PEG) having a molecular weight between about 1000 and about 6000 and the low molecular weight polar substance may be dimethyl hexanediol.