US 2026/0061664 A1 · Vapor Cooling 3D Printing for Bio Active and Heat Labile Materials

Abstract

A method and material for 3D printing objects containing heat-sensitive molecules are disclosed. The composition consists of a water-saturated, polar thermoplastic polymer, such as highly hydrolyzed polyvinyl alcohol (PVA), into which functional molecules—proteins, peptides, pharmaceuticals, fragrances, or living cells—are dispersed. The polymer is first hydrated to form a gel, extruded and cut into pellets, then partially dried through a multi-stage dehydration process that leaves a moisture-rich core and a dry outer shell. During extrusion at typical FDM nozzle temperatures (≈200° C.), entrapped water within the material vaporizes at ≈100° C., providing in situ evaporative cooling and maintaining the temperature of the functional molecules below their degradation point. The process enables additive manufacturing of structurally sound objects that preserve the activity of heat-sensitive additives, opening new applications for 3D-printed consumables, pharmaceuticals, and bio-functional components.

Claims11

Dependent claims

A 3D-printable material composition for forming objects containing heat-sensitive molecules, the composition comprising:

a polar thermoplastic polymer matrix having an internal water content sufficient to evaporatively cool the composition during extrusion;
and one or more heat-sensitive molecules distributed in the polymer matrix;
wherein the water content in the polymer matrix is retained within the matrix prior to extrusion and is released as water vapor when the composition is heated during 3D printing, thereby absorbing heat and preventing the heat-sensitive molecules from being denatured or destroyed by the extrusion temperature.

A method of preparing a 3D printing feed material that enables extrusion of heat-sensitive components without thermal damage, the method comprising:

(a) saturating a quantity of a water-absorbing thermoplastic polymer with water to form a water-infused polymer;
(b) forming the water-infused polymer into pieces suitable for feeding into a 3D printer, wherein the pieces retain water internally;
(c) partially drying an exterior of said pieces while maintaining an interior water content, including using a multi-stage drying process in which lower portions of the pieces are heated to release water vapor that is absorbed by upper portions, thereby producing conditioned pieces that have a moisture-rich core and a solid outer surface;
(d) after cooling, combining the conditioned pieces with one or more heat-sensitive molecules to form a composite mixture;
and (e) extruding or printing the composite mixture through a 3D printer at an extrusion temperature above 150 ° C., whereby water within the composite mixture vaporizes during step (e) and absorbs heat such that the heat-sensitive molecules are kept below their thermal degradation temperature during the extrusion.

2 more elements

Dependencies are inferred from the claim text.

Vapor Cooling 3D Printing for Bio Active and Heat Labile Materials

Life of this patent

Vapor Cooling 3D Printing for Bio Active and Heat Labile Materials

Life of this patent

Abstract

Claims11