Compositions and Methods for Selective Deposition Modeling

• US 20100288194A1
• Filed: 05/11/2010
• Published: 11/18/2010
• Est. Priority Date: 05/12/2009
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Stockwell, John, Xu, Pingyong
• Granted Patent: US 8,575,258 B2
• Time in Patent Office: Days
• US Class Current: 118/313
• 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 71/0009 using liquids, e.g. solvents, swelling agents spectacle cases, e.g. for cleaning contact lenses A45C11/04; disinfecting or sterilising contact lenses A61L12/00, using liquid substances A61L2/20; cleaning involving the use of liquid in general B08B3/00; for hydrating contact lenses B29D11/00067
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• 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
• CPC Class Codes: C08L 91/08 Mineral waxes
• CPC Class Codes: Y10T 156/1111 Using solvent during delaminating [e.g., water dissolving adhesive at bonding face during delamination, etc.]

Abstract

There is provided compositions and methods for producing three-dimensional objects by selective deposition modeling with a polar build material and a non-polar support material. The build material comprises a hydrocarbon wax material and a viscosity modifier, and the support material comprises a hydrocarbon alcohol wax material and a viscosity modifier. After the selective deposition modeling process has been completed, the object can be placed in a bath of polar solvent to remove the support material. The particular materials provided herein, and the post-processing methods associated therewith, provide for improved part quality of the three-dimensional object and for improved post-processing techniques. The three-dimensional objects can subsequently be used in a number of applications, such as patterns for investment casting.

Claims

1. A combination of compositions used to produce a three-dimensional object with a selective deposition modeling apparatus, the combination comprising:

(a) a build material comprising;

(i) a build hydrocarbon wax material defining a melting temperature of between about 70°

C. and about 80°

C., wherein the build hydrocarbon wax material comprises between 75% and 85% by weight of the build material, and

(ii) at least one build viscosity modifier defining a softening temperature of between about 90°

C. and about 145°

C. and defining a hydrocarbon resin free of oxygen, wherein the build viscosity modifier comprises between 15% and 25% by weight of the build material,

wherein the build material defines a viscosity of between about 11 and about 14 centipoise at 80°

C. and the build material defines a melting temperature of between about 65°

C. and about 85°

C.; and

(b) a support material comprising;

(i) a support hydrocarbon alcohol wax material defining a melting temperature of between about 52°

C. and about 65°

C., wherein the support hydrocarbon wax material comprises between 60% and 68% by weight of the support material, and

(ii) at least one support viscosity modifier defining a hydrogenated rosin that comprises between about 60 and about 200 acid number, wherein the support viscosity modifier comprises between 32% and 40% by weight of the support material,

wherein the support material defines a viscosity of between about 11 and about 14 centipoise at 80°

C.

2. A combination of compositions in accordance with claim 1, wherein the build hydrocarbon wax material comprises a paraffin wax.

3. A combination of compositions in accordance with claim 1, wherein the build viscosity modifier defines a softening temperature of between about 115°

C. and about 125°

C.

4. A combination of compositions in accordance with claim 1, wherein the build viscosity modifier comprises a hydrogenated hydrocarbon resin.

5. A combination of compositions in accordance with claim 1, wherein the build hydrocarbon wax material comprises about 81% by weight of the build material and the build viscosity modifier comprises about 19% by weight of the build material.

6. A combination of compositions in accordance with claim 1, wherein the support hydrocarbon alcohol wax material comprises at least one of octadecanol and hexadecanol.

7. A combination of compositions in accordance with claim 1, wherein the support viscosity modifier defines a hydrogenated rosin having about 120 acid number.

8. A combination of compositions in accordance with claim 1, wherein the support hydrocarbon wax material comprises about 65% by weight of the support material and the support viscosity modifier comprises at 35% by weight of the support material.

9. A combination of compositions in accordance with claim 1, wherein the build material defines a viscosity of about 12 centipoise at 80°

C. and wherein the support material defines a viscosity of about 12.5 centipoise at 80°

C.

10. A combination of compositions used to produce a three-dimensional object with a selective deposition modeling apparatus, the combination comprising:

(a) a build material consisting essentially of;

(i) a build hydrocarbon wax material comprising between 75% and 85% by weight of the build material, and

(ii) at least one build viscosity modifier defining a softening temperature of between about 90°

C. and about 145°

C. and defining a hydrocarbon resin free of oxygen, wherein the build viscosity modifier comprises between 15% and 25% by weight of the build material.

wherein the build material defines a viscosity of between about 11 and about 14 centipoise at 80°

C. and

(b) a support material consisting essentially of;

(i) a support hydrocarbon alcohol wax material comprising between 60% and 68% by weight of the support material, and

(ii) at least one support viscosity modifier defining a hydrogenated rosin that comprises between about 60 and about 200 add number, wherein the support viscosity modifier comprises between 32% and 40% by weight of the support material,

wherein the support material defines a viscosity of between about 11 and about 14 centipoise at 80°

C.

11. A combination of compositions in accordance with claim 10 wherein the build hydrocarbon wax comprises a paraffin wax.

12. A combination of compositions in accordance with claim 10 wherein the build viscosity modifier comprises a hydrogenated hydrocarbon resin.

13. A combination of compositions in accordance with claim 10 wherein the support hydrocarbon alcohol wax comprises at least one of octadecanol and hexadecanol.

14. A combination of compositions in accordance with claim 10 wherein the support viscosity modifier defines a hydrogenated rosin having about 120 acid number.

15. An apparatus for producing three-dimensional objects from a build material that is supported by a support material during production of the three-dimensional object, the apparatus comprising:

(c) a platform upon which the build material and support material are selectively dispensed;

(b) a dispensing device that selectively dispenses the build material and support material upon the platform;

(c) a build material supply that includes a build material comprising;

(i) a build hydrocarbon wax material defining a melting temperature of between about 70°

C. and about 80°

C., wherein the build hydrocarbon wax material comprises between 75% and 85% by weight of the build material, and

(ii) at least one build viscosity modifier defining a softening temperature of between about 90°

C. and about 145°

C. and defining a hydrocarbon resin free of oxygen, wherein the build viscosity modifier comprises between 15% and 25% by weight of the build material,

wherein the build material defines a viscosity of between about 11 and about 14 centipoise at 80°

C. and the build material defines a softening temperature of between about 65°

C. and about 85°

C.,

wherein the build material supply provides the build material in a generally flowable state to the dispensing device; and

(d) a support material supply that includes a support material comprising;

(i) a support hydrocarbon alcohol wax material defining a melting temperature of between about 52°

C. and about 65°

C., wherein the support hydrocarbon wax material comprises between 60% and 68% by weight of the support material, and

(ii) at least one support viscosity modifier defining a hydrogenated rosin that comprises between about 60 and about 200 acid group members, wherein the support viscosity modifier comprises between 32% and 40% by weight of the support material,

wherein the support material defines a viscosity of between about 11 and about 14 centipoise at 80°

C.,

wherein the support material supply provides the support material in a generally flowable state to the dispensing device.

16. An apparatus in accordance with claim 15 wherein the platform is moveable relative to the dispensing device.

17. An apparatus in accordance with claim 15 wherein the dispensing device comprises at least one ink jet print head that comprises orifices for dispensing the build material and that comprises orifices for dispensing the supply material.

18. An apparatus in accordance with claim 15 wherein at least one of the build material supply and the support material supply includes a heater device for heating the build material and support material, respectively, prior to supplying the respective material to the dispensing device.

19. An apparatus in accordance with claim 15 wherein the build hydrocarbon wax comprises a paraffin wax and wherein the build viscosity modifier comprises a hydrogenated hydrocarbon resin.

20. An apparatus in accordance with claim 15 wherein the support hydrocarbon alcohol wax comprises at least one of octadecanol and hexadecanol and wherein the support viscosity modifier defines a hydrogenated rosin having about 120 add number.

21-30. -30. (canceled)