Programmed material consolidation systems employing object release elements securable to platens for facilitating removal of fabricated objects therefrom

• US 20060231025A1
• Filed: 06/09/2006
• Published: 10/19/2006
• Est. Priority Date: 09/16/2003
• Status: Abandoned Application

• Current Assignee: Kevin G. Duesman, Warren M. Farnworth
• Original Assignee: Kevin G. Duesman, Warren M. Farnworth
• Inventors: Farnworth, Warren M., Duesman, Kevin G.
• Application Number:
  US11/450,719
• Publication Number:
  US 20060231025A1
• Time in Patent Office: Days
• US Class Current: 118/500
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• 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: G03F 7/0037 Production of three-dimensional images
• CPC Class Codes: G03F 7/092 characterised by backside coating or layers, by lubricating-slip layers or means, by oxygen barrier layers or by stripping-release layers or means
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers

Abstract

A programmable material consolidation system includes a platen and an object release element on the platen. The object release element includes a lower surface configured to be secured to the platen and readily removed from the platen. An adhesive coating, which may cover at least a portion of the lower surface, may be formed from a material, such as a radiation-curable polymer, that is tacky when in an uncured state and not as tacky when in a substantially cured state. A nonstick coating on the platen may facilitate ready removal of the object release element therefrom. An upper surface of the object release element may include a material to which an object will adhere, but which may be readily removed from the object once fabrication thereof is complete.

Claims

1. A programmable material consolidation system, comprising:

a fabrication site;

a platen within the fabrication site and including a support surface;

a nonstick coating on at least a portion of the support surface; and

an object release element positioned over the support surface and including an adhesive coating on at least a portion of a lower surface thereof, the adhesive coating securing the object release element to the nonstick coating.

2. The programmable material consolidation system of claim 1, wherein the fabrication site is configured to receive or contain a quantity of unconsolidated material.

3. The programmable material consolidation system of claim 2, wherein the unconsolidated material comprises a photopolymer.

4. The programmable material consolidation system of claim 3, wherein the unconsolidated material comprises ultraviolet-curable material.

5. The programmable material consolidation system of claim 1, wherein the nonstick coating comprises a fluorine-containing polymer.

6. The programmable material consolidation system of claim 1, wherein the object release element includes a substrate with an upper surface to which at least one fabricated object will adhere during fabrication thereof and which is readily removable from the at least one fabricated object following fabrication thereof.

7. The programmable material consolidation system of claim 6, wherein the substrate comprises a material to which the at least one fabricated object will adhere during fabrication thereof and which is readily removable from the at least one fabricated object following fabrication thereof.

8. The programmable material consolidation system of claim 7, wherein the substrate comprises at least one of polyethylene, polyethyleneteraphthalate, and polyethylene ethyl ketone.

9. The programmable material consolidation system of claim 6, further comprising:

an object release coating on at least a portion of an upper surface of the substrate, the object release coating comprising a material to which the at least one fabricated object will adhere during fabrication thereof and which is readily removable from the at least one fabricated object following fabrication thereof.

10. The programmable material consolidation system of claim 9, wherein the object release coating comprises at least one of polyethylene, polyethyleneteraphthalate, and polyethylene ethyl ketone.

11. The programmable material consolidation system of claim 1, wherein the adhesive coating comprises a polymer which is tacky when in an uncured state and nontacky when in a substantially cured state.

12. The programmable material consolidation system of claim 11, wherein the polymer comprises a radiation-curable polymer.

13. The programmable material consolidation system of claim 12, further comprising:

a source of electromagnetic radiation of at least one wavelength that will cure the radiation-curable polymer.

14. The programmable material consolidation system of claim 12, wherein the radiation-curable polymer comprises an ultraviolet-curable polymer.

15. The programmable material consolidation system of claim 11, wherein, when in the substantially cured state, the adhesive coating will have reduced adhesion to the nonstick coating.

24. The programmable material consolidation system of claim 6, further comprising:

an object release coating on at least a portion of an upper surface of the substrate, the object release coating comprising a material to which the at least one fabricated object will adhere during fabrication thereof and which is readily removable from the at least one fabricated object following fabrication thereof.

25. The programmable material consolidation system of claim 24, wherein the object release coating comprises at least one of polyethylene, polyethyleneteraphthalate, and polyethylene ethyl ketone.

16. A programmable material consolidation system, comprising:

a fabrication site;

a platen within the fabrication site and including a support surface and at least one port through which a negative pressure may be applied to the support surface; and

an object release element positioned over and secured to the support surface with the negative pressure.

17. The programmable material consolidation system of claim 16, wherein at least a lower surface of the object release element comprises a material that seals against the support surface at least when the negative pressure is applied to the lower surface.

18. The programmable material consolidation system of claim 16, wherein the fabrication site is configured to receive or contain a quantity of unconsolidated material.

19. The programmable material consolidation system of claim 18, wherein the unconsolidated material comprises a photopolymer.

20. The programmable material consolidation system of claim 19, wherein the unconsolidated material comprises ultraviolet-curable material.

21. The programmable material consolidation system of claim 16, wherein the object release element includes a substrate with an upper surface to which at least one fabricated object will adhere during fabrication thereof and which is readily removable from the at least one fabricated object following fabrication thereof.

22. The programmable material consolidation system of claim 21, wherein the substrate comprises a material to which the at least one fabricated object will adhere during fabrication thereof and which is readily removable from the at least one fabricated object following fabrication thereof.

23. The programmable material consolidation system of claim 22, wherein the substrate comprises at least one of polyethylene, polyethyleneteraphthalate, and polyethylene ethyl ketone.