System and method for printing and supporting three dimensional objects

• US 20040207124A1
• Filed: 11/20/2003
• Published: 10/21/2004
• Est. Priority Date: 03/21/2001
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Objet Geometries
• Inventors: Gothait, Hanan, Miller, Gershon, Kritchman, Eli
• Granted Patent: US 7,364,686 B2
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 35/04 using liquids, gas or steam
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• 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 64/112 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: B29C 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• 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 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 29/49982 Coating
• CPC Class Codes: Y10T 29/49993 Filling of opening

Abstract

A method for printing and supporting a three-dimensional (3-D) object is provided. The method of printing can include dispensing a first interface material for the construction of the three-dimensional object, dispensing a second interface material to form a support structure for supporting the three-dimensional object and dispensing a third interface material which May be Used to separate the support structure from the 3-D object Disclosed also a method for producing a 3-D model containing various kinds of inserts.

Claims

1. A method for building three-dimensional objects, said method comprising:

dispensing a first material used to form at least the three-dimensional object;

dispensing a second material used to form at least part of a support structure; and

dispensing a third material between said 3-D object and said support structure to form a release layer.

2. The method of claim 1 wherein at least said first material is a photopolymer and at least the three-dimensional object is formed after being irradiated by electromagnetic radiation.

3. The method of claim 1 wherein said second material is a photopolymer and the support structure is formed after being irradiated by electromagnetic radiation.

4. The method of claim 1 wherein said third material is a photopolymer and the release layer is formed after being irradiated by electromagnetic radiation.

5. The method of claim 1 wherein said support structure comprises said first material.

6. The method of claim 1 wherein said second and third materials are the same substance.

7. The method of claim 1 wherein said release layer is softer than said support structure, and said support structure is softer than said 3-D object.

8. The method of claim 1 comprising separating said support structure and release layer from said 3-D object thereby to produce a three dimensional object comprised of said first material.

9. The method according to claim 1, comprising subjecting said second material to a solvent or to radiation thereby to cause the support structure to weaken.

10. The method according to claim 1, wherein said support structure and release layer are at least partly liquid or paste after curing.

11. The method according to claim 1, where said support structure comprises a container capable of confining said support material.

12. The method according to claim 1, further comprising constructing at least one support pillar of said first material within said support structure..

13. The method according to claim 12, further comprising constructing at least one connecting membrane of first material attached to said at least one support pillar.

14. A system for building three-dimensional objects, said system comprising:

a controller; and

a jetting head capable of selectively dispensing;

a first material used to form at least the three-dimensional object;

a second material used to form at least part of a support structure; and

a third material between said 3-D object and said support structure used to form a release layer.

15. The system of claim 14 wherein at least said first material is a photopolymer and at least the three-dimensional object is formed after being irradiated by electromagnetic radiation.

16. The system of claim 14 wherein said second material is a photopolymer and the support structure is formed after being irradiated by electromagnetic radiation.

17. The system of claim 14 wherein said third material is a photopolymer and the release layer is formed after being irradiated by electromagnetic radiation.

18. The system of claim 14 wherein said support structure comprises said first material.

19. The system of claim 14, wherein said support structure and release layer are at least partly liquid or paste after curing.

20. The system of claim 14, where said support structure comprises a container capable of confining said support material.

21. A method for building three-dimensional objects, said method comprising:

dispensing a curable build material to form the 3-D object and part of the support structure;

dispensing a support material to form part of the support structure, the build material being solid after curing and the support material being liquid after curing; and

forming a support structure comprising a container capable of holding said support material.

22. The method according to claim 21, wherein said container comprises a base, a plurality of walls and an open top.

23. The method according to claim 21, wherein said container comprises at least one nib projecting from at least one of said walls, wherein said at least one nib is capable of restraining the movement of a three dimensional object.

24. The method according to claim 21, wherein said container comprises build material.

25. The method according to claim 21, wherein each of said build material, support material and container are formed in layers.

26. A system for building three-dimensional objects, said system comprising:

a controller; and

a material dispenser capable of dispensing;

a curable build material to form the 3-D object and part of a support structure; and

a support material to form part of the support structure, the build material being solid after curing and the support material being liquid after curing;

wherein the material dispenser is capable of forming a support structure comprising a container capable of holding said support material.

27. The system according to claim 26, wherein said container comprises a base, a plurality of walls and an open top.

28. The system according to claim 26, wherein said container comprises at least one nib projecting from at least one of said walls, wherein said at least one nib is capable of restraining the movement of a three dimensional object.

29. The system according to claim 26, wherein said container material is identical to said build material.

30. The system-according to claim 26, wherein each of said build material, support material and container material are deposited in layers.

31. A method for building three-dimensional objects, said method comprising:

dispensing a build material;

dispensing a second material forming a support structure; and

constructing a support pillar to support an object comprised of said build material.

32. The method according to claim 31, comprising constructing membranes connected to said support pillar.

33. The method according to claim 31, wherein said at least one support pillar is comprised of said build material.

34. The method according to claim 31, wherein said at least one support pillar is comprised of said build material and said second material.

35. The method according to claim 31, wherein said at least one support pillar comprises a plurality of layers and wherein the topmost layer of said at least one support pillar is adjacent to an object being supported.

36. The method according to claim 31, wherein said upper portion of said at least one support pillar is tapered.

37. The method according to claim 31, wherein each of said build material, second material and pillar are deposited in layers.

38. The method according to claim 31, wherein the topmost layer of said at least one support pillar comprises said second material.

39. The method according to claim 31, wherein the topmost layer of said at least one support pillar comprises a third material, said third material being softer than the material forming the remainder of said at least one support pillar.

40. A system for building three-dimensional objects, said system comprising:

dispenser capable of dispensing;

a build material;

second material forming a support structure; and

said dispenser constructing a support pillar to support an object comprised of said build material.

41. The system according to claim 40, wherein said dispenser is capable of material forming dispensing constructing membranes connected to said support pillar.

42. The system according to claim 40, wherein said at least one support pillar is comprised of said build material.

43. The system according to claim 40, wherein said at least one support pillar is comprised of said build material and said second material.

44. The system according to claim 40, wherein said at least one support pillar comprises a plurality of layers and wherein the topmost layer of said at least one support pillar is adjacent to an object being supported.

45. The system according to claim 40, wherein the topmost layer of said at least one support pillar comprises said second material.

46. The system according to claim 40, wherein the topmost layer of said at least one support pillar comprises a third material, said third material being softer than the material forming the remainder of the pillar.

47. The system according to claim 40, wherein said upper portion of said at least one support pillar is tapered.

48. The system according to claim 40, wherein each of said build material, second material and pillar are deposited in layers.

49. A method for building three-dimensional objects, said method comprising:

dispensing a first material for the construction of the three-dimensional object;

dispensing a support material forming a support structure for supporting said three-dimensional object; and

inserting a support insert.

50. The method of claim 49 wherein the support insert comprises a third material.

51. The method of claim 49 wherein the support insert includes plastic.

52. The method of claim 49 wherein the support insert includes metal.

53. The method of claim 49 wherein the support, insert is a plate shaped member.

54. The method of claim 49 wherein the support insert is a skewed member.

55. The method of claim 49 wherein the support insert includes at least threads.

56. The method of claim 49 wherein the support insert is flexible.

57. The method of claim 49 wherein the support insert is more rigid than the support material, after said support material is cured.

58. A system for building three-dimensional objects, said system comprising:

a build material jetting means for dispensing build material;

a support material jetting means for dispensing support material; and

a release material jetting means for dispensing release material between said built and support materials.

59. A system for building three-dimensional objects, said system comprising:

a controller means;

a material dispenser means for dispensing;

build material having a first modulus of elasticity;

container material having a second modulus of elasticity; and

support material having a third modulus of elasticity and being held in a container comprised of said container material.

60. A system for building three-dimensional objects, said system comprising:

a dispenser means for dispensing;

a build material;

a second material forming a support structure; and

said dispenser means constructing a support pillar to support an object comprised of said build material.