Photocurable resin for high-resolution 3-D printing
Inventors
Assignees
US Department of Veterans Affairs • University of Michigan Ann Arbor
Publication Number
US-12286512-B2
Publication Date
2025-04-29
Expiration Date
2041-05-27
Interested in licensing this patent?
MTEC can help explore whether this patent might be available for licensing for your application.
Abstract
Provided are photocurable resins comprising a poly(siloxane)-based copolymer together with a photoinitiator, and other optional ingredients such as a photocurable diluent, a photoabsorber, a photosensitizer, or a hydrophillic additive. Also provided are methods of stereolithographically printing a 3-D object from a disclosed resin. Also provided is an improved method for stereolithographically printing a 3-D object, the improvement comprising the use of a disclosed photocurable resin. Further provided is a 3-D microfluidic device such as an artificial lung prepared from a disclosed photocurable resin.
Core Innovation
The invention disclosed is a photocurable resin comprising a poly(siloxane)-based copolymer with a methacryloxypropyl-methysiloxane repeating unit and a dimethylsiloxane repeating unit, a photoinitiator (such as phosphine oxide photoinitiators), and optional additional components including a photocurable diluent, photoabsorber, photosensitizer, or hydrophilic additive. This resin is formulated to enable stereolithographic 3-D printing of objects with high resolution, particularly suitable for microfluidic applications.
The problem addressed is the insufficiency of material development in 3-D printing for microfluidics, especially the lack of commercially available resins that combine adequate gas permeability with high-resolution printing capabilities. Traditional microfluidic fabrication requires slow, manual steps and is limited largely to 2-D designs, driving a need for automated, scalable 3-D printing materials with gas permeability properties like those of polydimethylsiloxane (PDMS), which previously had not been successfully incorporated into photocurable resins for high-resolution 3-D printing.
Claims Coverage
The patent includes three independent claims covering the photocurable resin composition, the stereolithographic printing method using the resin, and a 3-D microfluidic device printed from the resin.
Photocurable resin composition
The resin comprises 5-99% by weight of a copolymer with methacryloxypropyl-methysiloxane repeating units constituting 1-10 mol % and dimethylsiloxane repeating units constituting the balance; 10-95% by weight of a methacryloxypropyl terminated dimethylsiloxane diluent (optional); 0.01-10% by weight of a phosphine oxide photoinitiator such as TPO, TPO-L, or combinations; and optional hydrophilic additives, photoabsorbers like Sudan I, and photosensitizers like ITX.
Method for stereolithographically printing a 3-D object using the disclosed resin
The method comprises providing the photocurable resin and sequentially photopolymerizing portions of the resin layer-by-layer to form integral photocured layers, enabling high-resolution 3-D printing.
3-D microfluidic device printed from the photocurable resin
A 3-D microfluidic device, such as an artificial lung, comprising flow channels for gas and blood transport, printed using the disclosed photocurable resin.
The independent claims collectively protect the novel resin composition, the improved high-resolution stereolithographic 3-D printing method employing the resin, and the resulting microfluidic devices, emphasizing improved print resolution, gas permeable materials, and microfluidic applications including artificial organs.
Stated Advantages
Improved printing resolution, achieving channel heights as small as 60 microns and membrane thicknesses down to 20 microns, which is superior to known photocurable resins.
Significant increase (10-fold) in printing resolution relative to existing commercial high-resolution resins (e.g., GR1 resin).
Reduced resin viscosity when including the methacryloxypropyl terminated dimethylsiloxane diluent, enhancing printability especially for small or complex features.
Tunable resin properties through combinations of photoabsorbers and photosensitizers to optimize resolution and curing depth.
Enhanced surface hydrophilicity via hydrophilic additives, improving wettability and reducing nonspecific protein adsorption for biomedical applications.
Documented Applications
Stereolithographic 3-D printing of microfluidic devices with small features including channels and membranes down to 20 microns.
Preparation of microfluidic artificial organs such as artificial lungs comprising gas and blood flow networks with channels less than 120 microns in diameter or height.
Fabrication of microfluidic systems including lab-on-a-chip devices, small volume reaction chambers, cell growth chambers, gas separation devices, diffusion systems, and extracorporeal support devices.
Interested in licensing this patent?