Wetting Agent Resin Composition for Bubble-Free 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Bubbles formed during 3D printing in curable compositions, such as those used in vat photopolymerization, lead to defects in 3D printed parts, affecting precision, aesthetics, and durability, and existing surfactant amounts are insufficient to prevent this issue.
Innovation Solution
Incorporating a specific wetting agent with a structure of formula (I) into the curable composition at 1 to 15 weight percent, which includes a polyalkoxylated ether of aliphatic alcohol, to prevent or restrict bubble formation during 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional surfactant amounts are used in curable compositions, then the composition maintains basic stability, but bubbles form during 3D printing affecting precision and quality
Solution Approach 1:
The patent changes the concentration parameter of surfactants in the curable composition, specifically using amounts of 0.1-10 wt% (preferably 0.5-5 wt%) to optimize bubble prevention while maintaining print quality and composition stability
Solution Approach 2:
The patent uses composite surfactant systems combining different types of surfactants (ionic, nonionic, amphoteric) with complementary mechanisms to enhance bubble prevention effectiveness beyond what single surfactants can achieve
2Reliability
If no additional surfactant is added, then the composition remains simple and cost-effective, but bubbles form and entrap in the cured product
Solution Approach 1:
The patent modifies the surfactant concentration parameter within an optimized range (0.1-10 wt%) to achieve reliable bubble prevention without excessive addition, balancing effectiveness with composition simplicity
Solution Approach 2:
The patent introduces surfactants as intermediary substances that mediate between the curable composition and bubbles, reducing surface tension and preventing bubble entrapment through their amphiphilic molecular structure
3Object-affected harmful factors
If more surfactant is added to prevent bubbles, then bubble formation is reduced, but the cost and complexity of the composition increases
Solution Approach 1:
The patent optimizes the surfactant concentration parameter to an effective range (0.1-10 wt%, preferably 0.5-5 wt%) that provides sufficient bubble prevention while avoiding excessive surfactant addition that would increase cost and complexity
Solution Approach 2:
The patent applies partial action by using moderate surfactant amounts (0.1-10 wt%) rather than large quantities, achieving adequate bubble prevention without the diminishing returns and increased complexity that would result from excessive surfactant addition
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 addition of the wetting agent effectively reduces bubble formation, enhancing the precision and quality of 3D printed parts without compromising throughput or creating waste, and is biodegradable and compatible with acrylate and epoxy binders.
Implementation Method 1
adding specific surfactants into the resin composition
Implementation Method 2
Both techniques use photopolymer resins to produce parts which are cured under UV light
Data Source
AI summary
The present invention relates to curable compositions comprising additives useful for preventing the formation and entrapment of bubbles during 3D printing and to methods for preventing or restricting bubble formation and entrapment in 3D printed compositions. More specifically, this invention pertains to a curable composition comprising: (A) a free-radically polymerizable resin comprising at least one (meth)acrylate-functionalized compound; (B) a free radical photoinitiator; (C) optionally, at least one cationically polymerizable compound and a cationic photoinitiator; and (D) at least one specific wetting agent present in an amount of 1 to 15 weight percent based on the weight of the curable composition. The additives described herein are useful across a wide range of 3D printed articles because the presence of bubbles in the curable composition may impact either or both of the operability or the aesthetics of a 3D printed article.