Water-based material systems and methods for 3D printing
First Claim
1. A powder system for use in a three-dimensional printer with an aqueous binder, said powder system comprising a water-soluble crosslinkable agent.
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Accused Products
Abstract
The present invention provides unique material systems and methods for 3D printing of articles having enhanced strength and durability. The powder systems comprise a water-soluble crosslinkable agent, and alternatively or additionally, a strengthening component. Preferably, the crosslinkable agent is selected from the group consisting of amino resins, phenol resins, and mixed amino/phenol resins. The strengthening component melts and flows when heated, and resolidifies or cures. Preferably, the strengthening component melts, flows and cures with heat.
In another aspect, the invention provides a powder/binder system comprising an oxidant and a reductant (a redox couple). When the binder is applied to the powder, the oxidant and reductant react to generate an acid that catalyzes crosslinking. As a result, the strength of the 3D article builds up at an enhanced rate. The oxidant may be in the powder, and the reductant in the binder; or the reductant may be in the powder, and the oxidant in the binder. Alternatively, both the oxidant and the reductant may be in the powder.
137 Citations
34 Claims
- 1. A powder system for use in a three-dimensional printer with an aqueous binder, said powder system comprising a water-soluble crosslinkable agent.
- 10. A powder system for use in a three-dimensional printer with an aqueous binder, said powder system comprising a strengthening component that melts and flows upon heating, then cures, or resolidifies upon cooling.
- 14. A powder system for use in a three-dimensional system with an aqueous binder, said powder system being acid sensitive, and comprising a redox pair, or one half of a redox pair.
- 21. A 3D article printed on a three-dimensional printer from a powder system and an aqueous binder system, wherein said powder system comprises a crosslinkable agent, and the article has an as-printed flexural strength of greater than 10 MPa.
- 23. A 3D article printed on a three-dimensional printer from a powder system and an aqueous binder system, wherein the 3D article has a flexural strength after thermal cure of at least about 20 MPa.
- 27. A 3D article printed on a three-dimensional printer from a powder system and an aqueous binder system, wherein the powder system comprises a conventional starch/cellulose or plaster powder and a strengthening component, and wherein the 3D article has a flexural strength after thermal cure of at least about 2.25 MPa.
- 31. A 3D article printed on a three-dimensional printer from a powder system and an aqueous binder system, wherein the powder system comprises starch/cellulose or plaster powder and a strengthening component, and wherein the 3D article has a flexural strength after thermal cure that is at least about 20% higher than the flexural strength of a similar article created and cured under the same conditions using a starch/cellulose or plaster powder that does not contain a strengthening component.
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33. A 3D article printed on a three-dimensional printer from a powder system and an aqueous binder system, wherein the powder system comprises a crosslinkable agent and a strengthening component, and wherein the 3D article after thermal cure is at least about four times stronger than a similar article made from a starch/cellulose or plaster powder having no crosslinkable agent or strengthening component.
Specification