Color or multi-material three-dimensional (3D) printing

• US 10,286,601 B2
• Filed: 05/24/2017
• Issued: 05/14/2019
• Est. Priority Date: 11/18/2013
• Status: Active Grant

• Current Assignee: San Draw Inc.
• Original Assignee: San Draw Inc.
• Inventors: Chang, Kai-Jui
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US15/604,598
• Publication Number:
  US 20170355134A1
• Time in Patent Office: 720 Days
• Field of Search: 264245, 264255, 264308, 264494
• CPC Class Codes: B01F 33/84 Mixing plants with mixing receptacles receiving material dispensed from several component receptacles, e.g. paint tins
• CPC Class Codes: B01F 35/7174 using pistons, plungers or syringes
• 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 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 67/0007 Manufacturing coloured articles not otherwise provided for, e.g. by colour change
• 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

Abstract

A three-dimensional (3D) continuous color printer includes one or more cartridges each with a building material stored therein, a mixer coupled to each cartridge, and a single printhead coupled to a mixer output, wherein the building material stored in the cartridge is transported to the mixer and the single print head to form a continuous color object.

Claims

1. A method for forming a three-dimensional object, comprising:

(a) providing a plurality of material cartridges that are in fluid communication with a nozzle of a print head, wherein said plurality of material cartridges comprises building materials, wherein said building materials are in a liquid state, and wherein at least a subset of said building materials are different;

(b) using at least a subset of said building materials from said plurality of material cartridges to generate a first mixture;

(c) extruding said first mixture from said nozzle towards a support to form a first layer of said first mixture adjacent to said support, wherein said first layer is part of said three-dimensional object;

(d) using at least a subset of said building materials from said plurality of material cartridges to generate a second mixture; and

(e) extruding said second mixture from said nozzle towards said support to form a second layer of said second mixture as part of said three-dimensional object, wherein at least a portion of said second layer is adjacent to at least a portion of said first layer.

2. The method of claim 1, wherein said plurality of material cartridges comprise building materials that are of different color, and wherein generation of said first mixture generates a third color of building materials.

3. The method of claim 1, wherein said plurality of material cartridges comprises building materials that are of different elasticity.

4. The method of claim 1, wherein said plurality of material cartridges comprises building materials that are of different hardness.

5. The method of claim 1, wherein a building material in a given one of said plurality of material cartridges comprises a polymeric material.

6. The method of claim 1, wherein a building material in a given one of said plurality of material cartridges comprises a fluid or paste that is solidifiable upon contact with an initiating agent.

7. The method of claim 1, wherein a building material in a given one of said plurality of material cartridges comprises a crosslinking agent, initiator, accelerator, or any combination thereof.

8. The method of claim 1, wherein a given one of said building materials is in a liquid state.

9. The method of claim 1, wherein said plurality of material cartridges are in fluid communication with said nozzle through a mixer.

10. The method of claim 1, wherein said generation of said first mixture is via in-line mixing or active mixing.

11. The method of claim 1, wherein (c) comprises (i) directing said first mixture towards said support and (ii) radiating said first mixture adjacent to said support to form said first layer.

12. The method of claim 11, wherein (e) comprises (i) directing said second mixture towards said support and (ii) radiating said second mixture adjacent to said support to form said second layer.

13. The method of claim 1, wherein said first layer is in accordance with a model design of said three-dimensional object.

14. The method of claim 13, wherein said model design is in a digital file.

15. The method of claim 1, wherein said building materials are stored in syringes that eject said building material during extrusion.

16. The method of claim 1, wherein said print head comprises a single heat extruder.

17. The method of claim 1, wherein said support is maneuvered along a z-axis by a z-axis motor.

18. The method of claim 1, wherein said support does not rotate around its axis.

19. The method of claim 3, wherein said print head is moveable with respect to said support, wherein said plurality of material cartridges are fixed with respect to said support.

20. The method of claim 1, wherein said print head is fixed to a wheel along a y-axis belt and moves within an X-Y plane with respect to said support.