Compositions and methods for use in three dimensional model printing

• US 20080105818A1
• Filed: 10/02/2007
• Published: 05/08/2008
• Est. Priority Date: 03/13/2000
• Status: Abandoned Application

• Current Assignee: Objet Geometries
• Original Assignee: Objet Geometries
• Inventors: Cohen, Avi
• Application Number:
  US11/905,515
• Publication Number:
  US 20080105818A1
• Time in Patent Office: Days
• US Class Current: 249/117
• CPC Class Codes: B29C 33/448 destructible B29C33/52 takes precedence; in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29C 37/005 Compensating volume or shape change during moulding, in general
• CPC Class Codes: B29C 41/48 Compensating volume change, e.g. retraction
• CPC Class Codes: B29C 41/52 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/10 Processes of additive manufacturing
• 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 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29C 67/24 characterised by the choice of material
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• 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: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: B41M 3/16 Braille printing typewriters or selective printing mechanisms for Braille printing B41J3/32

Abstract

Embodiments of the invention are directed to a method of producing three-dimensional prototype molds for use in investment casting. The method includes dispensing modeling material and support material in a predetermined arrangement, in layers, to produce a three-dimensional mold having an outer shell. Generally, the out shell includes modeling material and the interior of the mold includes support material. Then the mold is cured.

Claims

1. A method of producing three-dimensional prototype molds for use in investment casting, the method comprising:

dispensing modeling material and support material in a predetermined arrangement, in layers, to produce a three-dimensional mold having an outer shell such that the outer shell comprises modeling material and the interior of the mold comprises support material; and

curing the mold.

2. The method of claim 1, wherein dispensing comprises dispensing such that the outer shell comprises predominantly modeling material.

3. The method of claim 1, wherein dispensing comprises dispensing such that the interior comprises predominantly support material.

4. The method of claim 1, wherein dispensing comprises dispensing such that the outer shell comprises only modeling material.

5. The method of claim 1, wherein dispensing comprises constructing a grid of modeling material within the support material.

6. The method of claim 1, wherein dispensing comprises dispensing such that the wall thickness of the outer shell is between 0.5 mm to 0.9 mm.

7. The method of claim 1 wherein curing the mold comprises curing the outer shell to form a solid shell of modeling material around a semi-solid filling of support material.

8. The method of claim 1, wherein the interior of the mold remains semi-solid after curing.

9. The method of claim 1, wherein the three-dimensional mold is produced by a three-dimensional printer.

10. The method of claim 1, further comprising a process of preparing a cast from said mold, said process comprising casting the cured mold in a heat resistant substance to form a cast.

11. The method of claim 10 further comprising heating the cast using a heat source to burn away or dissipate the mold.

12. The method of claim 11, wherein after heating the cast, the mold burns away without swelling.

13. The method of claim 11, wherein after heating the cast, the mold dissipates or burns away without leaving traces of the modeling and support materials inside the cast.

14. The method of claim 10, wherein the heat-resistant substance is ceramic material.

15. A prototype mold for use in investment casting having an outer shell comprising modeling material and an interior comprising support material, said prototype mold being produced by three dimensional printing.

16. The prototype mold of claim 15 wherein said outer shell comprises predominantly modeling material

17. The prototype mold of claim 15 wherein the outer shell is a solid shell of modeling material.

18. The prototype mold of claim 15 wherein the interior comprises a grid of modeling material within the support material.

19. The prototype mold of claim 15 wherein the interior remains semi-solid when cured.

20. The prototype mold of claim 15, wherein the wall thickness of the outer shell is between 0.5 mm to 0.9 mm.

21. The prototype mold of claim 15 wherein said mold is cast in a heat resistant substance.

22. The prototype mold of claim 21, wherein said heat resistant substance is a ceramic material.