Process and apparatus for fabrication of three dimensional objects

• US 10,357,918 B2
• Filed: 05/29/2018
• Issued: 07/23/2019
• Est. Priority Date: 10/27/2010
• Status: Active Grant

• Current Assignee: Raisa Milkin & Eugene Giller 2017 Trust
• Original Assignee: Rize, Inc.
• Inventors: Giller, Eugene
• Primary Examiner(s): Sanders, James
• Application Number:
  US15/991,448
• Publication Number:
  US 20180272596A1
• Time in Patent Office: 420 Days
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0855 using microwave
• CPC Class Codes: B29C 2035/0861 using radio frequency
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 37/0067 Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other separating agents B29C33/60
• 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 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• 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 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2073/00 Use of other polymers having oxygen as the only hetero atom in the main chain, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2995/002 Coloured
• 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 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24901 : including coloring matter
• CPC Class Codes: Y10T 428/24917 : including metal layer

Abstract

A fabrication process and apparatus for producing three-dimensional objects by depositing a first polymer layer, printing a first ink layer on to the first polymer layer, depositing a second polymer layer on to the first ink layer, and printing a second ink layer on to the second polymer layer. The deposition and printing steps may be repeated until a three-dimensional object is formed. The inks used to form at least one of the first and second ink layers may include dyes or pigments so that the three-dimensional object may be a colored three-dimensional object.

Claims

1. A system comprising:

an extruder assembly configured to extrude a first polymer layer; and

an ink printing apparatus comprising a print head and ink delivery system, the ink printing apparatus configured to print a first ink layer on to the first polymer layer;

wherein the extruder assembly is further configured to extrude a second polymer layer on to the first ink layer;

wherein the ink printing apparatus is further configured to print a second ink layer on to the second polymer layer;

wherein the system is configured to repeat extrusion of polymer and printing of ink to form a three-dimensional object.

2. The system of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink comprising at least one of pigments, dyes, catalysts, plasticizers, or active ingredients.

3. The system of claim 1, wherein at least one of the first ink layer and the second ink layer includes a color ink.

4. The system of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink, and wherein the ink is a plasticizing ink or a releasable ink.

5. The system of claim 1, wherein at least one of the first ink layer and the second ink layer and at least one of the first polymer layer and the second polymer layer are treated with an energy source during fabrication of the three-dimensional object.

6. The system of claim 1, wherein the first ink layer and the second ink layer provide different surface properties to the three-dimensional object.

7. The system of claim 1, wherein the system is configured to form a support structure adjacent to the three-dimensional object during fabrication of the three-dimensional object, and wherein a releasable ink layer is printed between the three-dimensional object and the support structure.

8. The system of claim 7, wherein the support structure is formed from a polymeric material, and wherein the support structure polymeric material is the same as a polymeric material used to form the three-dimensional object.

9. The system of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink that provides increased flexibility to the three-dimensional object.

10. The system of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink that creates a smooth surface on the three-dimensional object.

11. The system of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink selected based on an ink solubility parameter in relation to a polymer solubility parameter.

12. The system of claim 1, wherein at least one of the first ink layer and the second ink layer includes a plasticizing ink selected based on an ink solubility parameter in relation to a polymer solubility parameter.

13. The system of claim 1, wherein the ink printing apparatus is attached to the extruder assembly.

14. The system of claim 1, wherein the extruder assembly includes an extruder, the extruder including a die and a heat source.

15. The system of claim 14, wherein the ink printing apparatus is attached to the extruder.

16. The system of claim 14, wherein the ink printing apparatus is attached to the extruder assembly separate from the extruder.

17. The system of claim 1, wherein the extruder assembly includes a fusion deposition modeling apparatus, a laminated object manufacturing apparatus, and/or a photopolymer deposition apparatus.

18. The system of claim 1, wherein the print head and ink delivery system includes a print head including a thermal print head, a piezo print head, a MEMS print head, an electrostatic print head, a plotter-style single nozzle unit, a continuous ink jet, and/or a drop-on demand system.

19. The system of claim 1, wherein the print head and ink delivery system is further configured to print a target pattern onto a layer of the three-dimensional object.

20. The system of claim 19, further comprising:

an optical sensor, wherein the system is configured to scan the target pattern with the optical sensor.

21. The system of claim 20, wherein the system is further configured to align the extruder assembly with the target pattern.

22. The system of claim 20, wherein the system is further configured to align the print head with the target pattern.

23. A system comprising:

an extruder assembly configured to extrude a first polymer layer; and

an ink printing apparatus comprising a print head and ink delivery system, the ink printing apparatus configured to print a first ink layer on to the first polymer layer;

wherein the system is configured to repeat extrusion of polymer and printing of ink to form a three-dimensional object;

wherein the system is configured to treat at least one of the first ink layer and the first polymer layer with a heat source, an energy source, or a combination of the heat source and the energy source.

24. The system of claim 23, wherein the extruder assembly is further configured to extrude a second polymer layer on to the first ink layer and the ink printing apparatus is further configured to print a second ink layer on to the second polymer layer during fabrication of the three-dimensional object, wherein the system is further configure to treat at least one of the second ink layer and the second polymer layer with the heat source, the energy source, or the combination of the heat source and the energy source.

25. The system of claim 23, wherein the first ink layer includes an ink comprising at least one of infrared absorbers, near infrared absorbers, visible energy absorbers, microwave absorbers, or radiofrequency absorbers.

26. The system of claim 23, wherein the system is configured to apply the heat source, the energy source, or the combination of the heat source and the energy source during fabrication of the three-dimensional object or to a fabricated three-dimensional object.

27. The system of claim 23, further comprising the energy source and/or the heat source.

28. The system of claim 23, wherein the ink printing apparatus is attached to the extruder assembly.

29. The system of claim 23, wherein the extruder assembly includes an extruder, the extruder including a die and the heat source.

30. A system comprising:

an extruder assembly configured to extrude a first polymer layer; and

a print head and ink delivery system configured to print a first ink layer on to the first polymer layer;

wherein the system is configured to repeat extrusion of polymer to form a three-dimensional object.