Support material and applications thereof

• US 10,232,529 B2
• Filed: 11/16/2016
• Issued: 03/19/2019
• Est. Priority Date: 02/23/2011
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Xu, Pingyong, Moussa, Khalil, Stockwell, John
• Primary Examiner(s): Thrower, Larry W
• Application Number:
  US15/353,297
• Publication Number:
  US 20170066199A1
• Time in Patent Office: 853 Days
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 33/40 Plastics, e.g. foam or rubber
• CPC Class Codes: B29C 33/52 soluble or fusible in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2891/00 Use of waxes as mould material
• CPC Class Codes: B29K 2995/0062 water-soluble
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B41M 5/508 Supports
• CPC Class Codes: C08K 5/05 Alcohols; Metal alcoholates
• CPC Class Codes: C08L 91/06 Waxes
• CPC Class Codes: C09D 191/06 Waxes
• CPC Class Codes: C09D 7/43 : Thickening agents
• CPC Class Codes: C09D 7/63 : organic
• CPC Class Codes: C09K 5/066 : Cooling mixtures; De-icing compositions
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

In one aspect, support materials operable for use in 3D printing systems are described herein. In some embodiments, a support material comprises a wax component comprising at least one ethoxylated fatty alcohol and a viscosity modifying agent, wherein the support material is water dispersible. In some embodiments, the wax component comprises a mixture of at least one fatty alcohol and at least one ethoxylated fatty alcohol.

Claims

1. A method of printing a three dimensional article comprising:

selectively depositing layers of a fluid build material to form the three-dimensional article on a substrate; and

supporting at least one of the layers of the build material with a support material, the support material comprising;

a wax component comprising at least one ethoxylated fatty alcohol;

a viscosity modifying component; and

a phase change agent operable to accelerate the freezing of the support material when the support material is deposited in a three-dimensional printing system,

wherein the phase change agent comprises a urethane wax that freezes or solidifies over a range of 1°

C. to 3°

C., and

wherein the support material is water dispersible following deposition of the support material in the three-dimensional printing system.

2. The method of claim 1, wherein the layers of the build material are deposited according to an image of the three dimensional article in a computer readable format.

3. The method of claim 2, wherein the build material is deposited according to preselected computer aided design (CAD) parameters.

4. The method of claim 1 further comprising curing the build material.

5. The method of claim 1 further comprising removing the support material from the build material by contacting the support material with water.

6. The method of claim 5, wherein the support material is dispersed in the water to provide an aqueous dispersion.

7. The method of claim 6 further comprising disposing of the aqueous dispersion of the support material in a wastewater treatment system without further treatment prior to entry of the aqueous dispersion into the wastewater treatment system.

8. The method of claim 1, wherein the build material solidifies upon deposition.

9. The method of claim 1, wherein the build material remains substantially fluid upon deposition.