Water-Soluble Support Material for 3D Inkjet Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current support materials in 3D inkjet printing are difficult to remove efficiently without damaging the object, often requiring harsh chemicals, high temperatures, or labor-intensive processes, which can affect the mechanical properties of the final product and pose environmental and safety concerns.
Innovation Solution
A novel support material formulation comprising a curable mono-functional monomer, a non-curable water-miscible polymer, and a silicone polyether, which can be easily dissolved in water, eliminating the need for harsh chemicals and high temperatures, and maintaining the mechanical properties of the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional support materials are used in 3D inkjet printing, then the support material provides adequate mechanical strength to hold the model material, but the removal process becomes difficult and time-consuming, requiring harsh chemicals or high temperatures that can damage the object
Solution Approach 1:
The invention changes the chemical composition parameters of the support material by incorporating water-soluble polymers (such as polyacrylic acid, polyacrylamide, or carboxymethyl cellulose) into the formulation. This parameter change enables the support material to maintain adequate mechanical strength when cured while allowing for easy removal through simple water dissolution, eliminating the need for harsh chemicals or high temperatures that would damage the final object.
Solution Approach 2:
The invention uses a composite support material formulation that combines UV-curable monomers with water-soluble polymers and plasticizers. This composite approach creates a material that exhibits both the necessary mechanical strength for supporting the model during printing and the ability to be easily removed through water dissolution, resolving the contradiction between strength and ease of removal.
2Productivity
If the support material is designed to harden rapidly to allow building of subsequent layers, then the manufacturing process efficiency improves, but the hardened support material may require more aggressive removal processes
Solution Approach 1:
The invention modifies the chemical parameters of the support material formulation by incorporating water-soluble polymers and adjusting the UV-curable monomer composition. This enables the material to cure rapidly under UV irradiation for efficient layer building, while the water-soluble components ensure that the hardened material can be easily removed through simple water dissolution, significantly reducing removal time without requiring aggressive processes.
3Ease of operation
If phase change materials like wax are used as support material, then the support material can be removed by melting at high temperature, but the high temperature may cause deformation of the model and object structure
Solution Approach 1:
The invention changes the removal mechanism parameter from thermal melting to chemical dissolution. By incorporating water-soluble polymers into the support material formulation, the material can be removed through dissolution in water at ambient temperature, completely avoiding the high temperature processing that would cause deformation of the model and final object structure.
Solution Approach 2:
The invention replaces the thermal-based removal mechanism (melting wax at high temperature) with a chemical-based mechanism (dissolution of water-soluble polymers in water). This substitution eliminates the need for high temperature processing, thereby preventing temperature-induced deformation of the model and final product while maintaining easy removal capability.
4Productivity
If mechanical impact methods are used for support material removal, then the removal process can be faster, but the process becomes labor-intensive and unsuited for small intricate parts
Solution Approach 1:
The invention enables the support material to be easily removed through self-dissolution in water, eliminating the need for complex mechanical impact devices or labor-intensive manual removal processes. The water-soluble polymer formulation allows the support material to automatically dissolve and be washed away, providing a simple, automated removal process suitable for all part sizes including small intricate parts.
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 new formulation allows for efficient and automated removal of the support material, reducing processing time and environmental impact while preserving the object's mechanical integrity.
Implementation Method 1
a curable, water-soluble mono-functional monomeric material
Implementation Method 2
a non-curable water-miscible polymeric material
Data Source
AI summary
Novel support material formulations, characterized as providing a cured support material which is readily removable by contacting with water, are disclosed. The formulations comprise a curable water-soluble mono-functional monomer, a water-miscible polymer and a silicone polyether. Methods of fabricating a three-dimensional object, and a three-dimensional object fabricated thereby are also disclosed.