THREE-DIMENSIONAL PRINTING

• US 20110042859A1
• Filed: 11/02/2010
• Published: 02/24/2011
• Est. Priority Date: 02/15/2001
• Status: Abandoned Application

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Huntsman Advanced Materials Americas LLC (Huntsman Corporation)
• Inventors: Peace, Richard J., Patel, Ranjana
• Application Number:
  US12/917,873
• Publication Number:
  US 20110042859A1
• Time in Patent Office: Days
• US Class Current: 264/401
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• 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

Abstract

A process for forming a three-dimensional article in sequential layers in accordance with a digital model of the article. The process comprises the steps of defining a layer of a first liquid, applying a second liquid to the first liquid layer in a pattern corresponding to the digital model, and repeating these steps to form successive layers. The first liquid comprises a first active component and the second liquid includes a second active component capable of reacting with the first reactive component so that the article is built up in layers.

Claims

1. A process for forming a three-dimensional article in sequential layers in accordance with a model of the article, the process comprising the steps of:

defining a continuous layer of a first liquid material;

applying a second liquid to locations of the first liquid layer in a pattern corresponding to the model; and

repeating these steps to form successive layers; and

in which the first liquid includes a first active component and the second liquid includes a second active component which is capable of reacting with the first reactive component so that the first layer cures in locations to which the second liquid has been applied but does not cure in the locations to which the second liquid has not been applied, the second liquid having a viscosity in the range of 2 to 500 cps at room temperature and wherein the first liquid and/or the second liquid further comprise nanoparticles.

2. A process as claimed in claim 1, in which the first liquid substantially comprises the first active component and/or the second liquid substantially comprises the second active component.

3. A process as claimed in claim 2, in which the second liquid includes a proportion of the first liquid and/or first active component.

4. A process as claimed in claim 3, in which the model is a digital model.

5. A process as claimed in claim 4, in which the first and/or second active components comprise respective mixtures of active components.

6. A process as claimed in claim 5, in which the second liquid additionally comprises a viscosity lowering diluent.

7. A process as claimed in claim 1, further including the step of irradiating the article.

8. A process as claimed in claim 7, in which the article is irradiated, pixel by pixel, line by line or layer by layer.

9. A process as claimed in claim 8, in which the article is irradiated after several layers have been formed.

10. A process as claimed in claim 9, in which the article is irradiated after all the layers have been formed.

11. A process as claimed in claim 7, in which the irradiating step employs electromagnetic radiation.

12. A process as claimed in claim 7, in which the irradiating step employs UV radiation.

13. A process as claimed in claim 12, including the step of varying the number of pixel drops and/or varying the applied liquid per pixel, per line applied and/or per layer, in order to achieve variable properties in the article.

14. A process as claimed in claim 13, in which the first liquid further comprises a curable cross-linkable or polymerisable compound and the second liquid comprises an initiator.

15. A process as claimed in claim 14, in which the first active component is selected from:

ring opening compounds, polymerizing compounds, hybrid compounds, condensing resins, and mixtures thereof.

16. A process as claimed in claim 15, in which the first liquid and/or second liquid contains an organic or inorganic filler, pigment, dye, surfactant and/or dispersant.

17. A process as claimed in claim 16, in which the first liquid and/or second liquid is coloured.

18. A process as claimed in claim 17, in which the second active component is a radical and/or cationic photoinitiator and/or a catalyst.

19. A process as claimed in claim 18, in which the thickness of the applied layers from the first liquid is in the range 0.1 to 200 μ

m.

20. A process as claimed in claim 1, in which the second liquid is applied by jetting or micro-spraying.