3D Inkjet Printing Method with Free Space Droplet Merging for Low Viscosity and Highly Reactive Materials

Abstract

Silicones are industrially important polymers characterized by a wide spectrum of chemical and physical properties with a number of important applications including automotive components, construction materials, isolating parts in electronic devices, flexible electronics, and medical products. Development of additive manufacturing methods for silicones enable production of complex and custom designed shapes and structures at both the micro- and macro-scale, economically feasible. In general, such materials can be fabricated using stereolithographic, extrusion-based, or inkjet printing techniques, in which silicones are polymerized using either photo- or heat-initiators. Silicones can also be crosslinked based on chemical reactions. Although this approach is supposedly the simplest, it has not been widely applied in additive manufacturing, as suitable technology for mixing and curing reactive inks without clogging nozzles has not be developed yet. To address this issue, a new 3D printer, that enables the fabrication of highly reactive and low viscous materials, has been developed and tested experimentally. The proposed fabrication method involves the ejection of two reactive droplets simultaneously from individual dispensers, merging and mixing them in free space outside the nozzle followed by deposition of the merged drop in a patterned format on a substrate. It was shown that the printing process is robust and stable more than 4 hours and it can be used on demand. By incorporating an XYZ positioner, it was possible to deposit droplets in an overlapping fashion to print any programmable shape featuring homogeneous structure, with a small number of pores. Moreover, due to the almost instantaneous reaction between two components (< 10s), the fabrication of very high aspect ratio (AR > 50) objects is possible. Lastly, the presented method can be easily adapted to print in free space without the use of support materials.