Specialty chemicals company LANXESS provides next-generation low-free (LF) isocyanate-based polyurethane prepolymers that can be formulated into resins for 3D printing/additive manufacturing. To produce this resin, LANXESS works with 3D printing companies. These high-performance resins are based on Adiprene LF pPDI (terephthalic diisocyanate) prepolymers, are easy to process, and are safe for industrial manufacturers and general home, office, or retail users.
High-performance resins for the shoe industry
The footwear industry is the main user of 3D printing technology in structural components such as midsoles, uppers, heels and toes. The design of footwear components requires both very soft elastomers and more rigid elastomers. The wide flexibility of formulating LF prepolymers into printable resins has enabled 3D printers to move toward mass customization, enabling everything from very soft elastomers for cushioning to more structural footwear components A variety of hardness prints.
High bending strength and a wide range of operating temperatures are important for the performance of these components. The design of Adiprene LF pPDI prepolymer has excellent low temperature and high temperature resistance, excellent toughness, chemical resistance and wear resistance. For example, sports shoes can maintain excellent performance at 150°C for up to 6 weeks, and can be stored in a hot car for a long time without causing any damage. In addition, footwear components have higher resistance to flex fatigue and low-temperature deflection performance down to – 20°C.
LANXESS provides polyurethane prepolymers and other chemicals for 3D printing, including LF MDI and LF HDI. These elastomers can provide unique properties such as optical transparency, UV and hydrolytic stability for outdoor use, and the ability to eliminate surface defects.
Easy processing and higher productivity
Temporary users of desktop 3D printing want to use simple and easy-to-use resins to improve production efficiency. This means that the resin must be liquid at room temperature or have a low melting point (<40°C) and must have a very low viscosity (<3000 cP). One-component (1K) resin can be added directly to the machine without mixing.
The high-performance LF pPDI prepolymer can be designed to have a lower viscosity, making it easier to process and increase productivity. LF technology enables chemists to control the reactivity of inks, allowing 3D printers the flexibility to custom design polyurethane product portfolios (1K, 2K or 3K). By enabling users to keep the resin stable for several days without curing, while allowing curing to occur within a few seconds after coating, the gel time can be adjusted to increase productivity.
Adiprene LF pPDI prepolymer can be cured at room temperature, or it can be formulated as a dual curing system using both ultraviolet and heat. Printable resins made with LF prepolymers are more stable, provide better surface finish, and can be designed to require minimal post-curing, thereby further increasing productivity.
Excellent user security
The company is looking for the safest materials for customers who are not familiar with chemical handling, especially in uncontrolled home, office and retail environments. LF technology supports 3D desktop printing in low-risk situations. Adiprene LF pPDI prepolymer contains less than 0.1% residual isocyanate, which reduces the hazard level and protects users from potential exposure risks.
The LANXESS polyurethane business is a leader in the development of low-free (LF) isocyanate urethane prepolymers with a free isocyanate content of <0.1%. LF technology produces polymer morphology that can be precisely controlled, leading to highly structured phase separation between crystalline hard segments and amorphous soft segments. This customized chemical structure provides better physical properties, is easier to process, and reduces the hazard level of formulated polyurethane systems.
LANXESS is the only manufacturer to provide low free (LF) isocyanate prepolymer systems based on pPDI. The system has global production capacity and can be quickly customized to develop new products according to specific customer needs.