Three-dimensional structured printing

• US 20040036200A1
• Filed: 09/15/2003
• Published: 02/26/2004
• Est. Priority Date: 02/15/2001
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Huntsman Advanced Materials Americas, Inc.
• Inventors: Zhao, Yong, Peace, Richard J., Patel, Ranjana, Rhodes, Michael, Powell, Jeremy
• Granted Patent: US 7,455,804 B2
• Time in Patent Office: Days
• US Class Current: 264/401
• 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: B29K 2105/162 Nanoparticles
• 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 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

Abstract

A process for forming a three-dimensional article in sequential layers in accordance with a digital model of the article. The process comprises the steps of defining a layer of powder material, applying a liquid reagent to the powder layer in a pattern corresponding to the digital model, and repeating these steps to form successive layers. The powder comprises a first reactive component and the liquid includes a second active component capable of reacting with the first reactive component so that the article is built up in layers.

Claims

1. A process for forming a three-dimensional article in sequential cross-sectional layers in accordance with a model of the article, the process comprising the steps of:

defining a layer of powder material;

applying a liquid reagent to the powder layer in a pattern corresponding to the respective cross-sectional layer of the model; and

repeating these steps to form successive layers;

characterised in that the powder substantially comprises a first reactive component and the liquid includes a second active component, the second active component being capable of either reacting with the first reactive component or facilitating the first reactive component to react with itself.

2. A process as claimed in claim 1, characterised in that the liquid reagent additionally comprises a viscosity lowering diluent.

5. A process as claimed in any preceding Claim characterised, in that the model is a digital model.

6. A process as claimed in any preceding Claim, characterised in that the second active component acts as a catalyst to facilitate cross-linking of the first reactive component.

7. A process as claimed in any preceding claim, characterised in that at least one of the layers of powder comprises a different material.

8. A process as claimed in any preceding claim, characterised in that a plurality of different liquids is applied to respective powder layers.

9. A process as claimed in any preceding claim, characterised in that a plurality of different liquids is applied to a single powder layer.

10. A process as claimed in claim 9, characterised in that the different liquids are applied in a single pass.

11. A process as claimed in claim 9, characterised in that the different liquids are applied in respective sequential passes.

12. A process claimed in any preceding claim, characterised in that the layers formed have differing thicknesses.

13. A process as claimed in any preceding claim, characterised in that a layer is formed with a varying thickness over its extent.

14. A process as claimed in any preceding claim, characterised further by the step of irradiating the article.

15. A process as claimed in claim 14, characterised in that the article is irradiated, pixel by pixel, line by line or layer by layer, either randomly or clustered.

16. A process as claimed in claim 14, characterised in that the article is irradiated after several layers have been formed.

17. A process as claimed in claim 14, characterised in that the article is irradiated after all the layers have been formed.

18. A process as claimed in any of claims 14 to 17, characterised in that the irradiating step employs electromagnetic radiation.

19. A process as claimed in any of claims 14 to 17, characterised in that the irradiating step employs UV radiation.

20. A process as claimed in any preceding claim, characterised in that the liquid reagent is applied through a plurality of nozzles.

21. A process as claimed in claim 20, characterised in that the nozzles form part of an inkjet printer or a device including a set of nozzles generally equivalent to an inkjet print head.

22. A process as claimed in claim 21, characterised in that the nozzles operate on the principles of piezo inkjet technology.

23. A process as claimed in any of claims 20 to 22, characterised in that the size of the nozzle openings is the range 0.01 to 100 μ

m and/or the size of the applied droplets is in the range 0.1 to 200 μ

m.

24. A process as claimed in any of claims 20 to 23, characterised by the further step of varying the number of pixel drops and/or varying the applied liquid per pixel, per line applied and/or per layer, in order to achieve variable properties in the article.

25. A process as claimed in any preceding claim, characterised in that the powder comprises reactive organic or organometallic polymers, oligomers or monomers and the liquid reagent comprises a curable resin.

26. A process as claimed in claim 25, characterised in that the powder contains an organic or inorganic filler, a pigment, nanoparticles, a dye and/or a surfactant.

27. A process as claimed in any of claims 2 to 26, characterised in that the diluent in the liquid has reactive groups capable of swelling and/or dissolving the powder.

28. A process as claimed in any preceding claim, characterised in that the liquid is coloured.

29. A process as claimed in any preceding claim, characterised in that the liquid contains colloidal or nano-particles, such as silica, organic core-shells (made from micro-emulsions), metals or alloys.

30. A process as claimed in any preceding claim, characterised in that the viscosity of the liquid is in the range of 2 to 500 cps at room temperature.

31. A process as claimed in claim 30, characterised in that the viscosity of the liquid is less than 30 cps.

32. A process as claimed in any preceding claim, characterised in that the liquid is jetted at a temperature in the range of 65 to 75°

C.

33. A process as claimed in any preceding claim, characterised in that the diluent is present in the range 30 to 60% by volume.

34. A process as claimed in any preceding claim, characterised in that the diluent is reactive.

35. A process as claimed in any preceding claim, characterised in that all of the liquid applied to the powder reacts to form a solid.

36. A process as claimed in any preceding claim, characterised in that the thickness of the applied powder layers is in the range 1.0 to 30 μ

m.

37. A process as claimed in any preceding claim, characterised in that the thickness of the formed layer is from 1.0 μ

m to 200 μ

m.

3. A process for forming a three-dimensional article structured in sequential cross-sectional layers in accordance with a model of the article, the process comprising the steps of:

defining a layer of powder material;

applying a liquid reagent to the powder layer in a pattern corresponding to the respective cross-sectional layer of the model; and

repeating these steps to form successive layers;

characterised in that the powder includes a first reactive component and the liquid includes a viscosity-lowering diluent and a second active component, the second active component being capable of either reacting with the first reactive component, or facilitating the first reactive component to react with itself.

4. A process as claimed in Claim 3, characterised in that the powder substantially comprises the first reactive component.