Solid imaging process using component homogenization

• US 5,980,812 A
• Filed: 04/30/1997
• Issued: 11/09/1999
• Est. Priority Date: 04/30/1997
• Status: Expired

• Current Assignee: John A. Lawton
• Original Assignee: John A. Lawton
• Inventors: Lawton, John A.
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US08/846,271
• Time in Patent Office: 923 Days
• Field of Search: 264/308, 264/401, 264/497, 419/46
• US Class Current: 264/401
• CPC Class Codes: B22F 1/09 Mixtures of metallic powders
• CPC Class Codes: B22F 1/12 Metallic powder containing non-metallic particles containing lubricating or binding agents or organic material B22F1/10
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 12/43 pulsed; frequency modulated
• CPC Class Codes: B22F 12/44 characterised by the configuration of the radiation means
• CPC Class Codes: B22F 12/67 Blades
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29K 2105/0064 Latex, emulsion or dispersion
• CPC Class Codes: B29K 2105/0088 Blends of polymers
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for 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
• CPC Class Codes: C22C 12/00 Alloys based on antimony or bismuth
• CPC Class Codes: C22C 21/00 Alloys based on aluminium
• CPC Class Codes: C22C 28/00 Alloys based on a metal not provided for in groups C22C5/00 - C22C27/00
• CPC Class Codes: C23C 26/00 Coating not provided for in groups C23C2/00 - C23C24/00
• CPC Class Codes: C23C 26/02 applying molten material to the substrate
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Solid objects are formed in an imagewise layering process in which components of a dispersion are homogenized to form an alloy. Imagewise exposure of the layers to radiation to form an alloy permits separation of the exposed, homogenized regions from non-exposed, non-homogenized regions. As each layer is formed and imagewise homogenized, contiguous layer regions are bonded together to form a homogenized, three-dimensional object which may be separated from surrounding dispersion.

Claims

1. A process for producing a homogenized, three-dimensional, integral object by imagewise thermal radiation of a dispersion, the dispersion containing components A and B, comprising the steps of:

a) providing the dispersion containing components A and B;

b) forming the dispersion into a layer;

c) homogenizing the dispersion by applying imagewise thermal radiation to form an alloy of components A and B; and

d) repeating steps a)-c) by applying each successive layer of the dispersion onto the previous layer of the dispersion, such that each new homogenized region becomes integral with the previous homogenized region to form the homogenized, three-dimensional, integral object.

2. The process as claimed in claim 1, further comprising separating the integral object from non-imaged areas of the dispersion.

3. The process as claimed in claim 1, wherein the alloy comprising the integral object has a different melting point than the dispersion of components A and B.

4. The process as claimed in claim 1, wherein components A and B are polymers, metals or ceramics.

5. The process as claimed in claim 1, wherein components A and B are polymers and the alloy formed by imagewise radiation is a polymer alloy.

6. The process as claimed in claim 5, wherein one of the polymer components is liquid and one of the polymer components is particulate.

7. The process as claimed in claim 1, wherein components A and B are metals and the alloy formed by imagewise radiation is a metal alloy.

8. The process as claimed in claim 1, wherein the alloy is a metal ceramic.

9. The process as claimed in claim 1, wherein component A is a solid and component B is a liquid.

10. The process as claimed in claim 9, wherein component A is particulate.

11. The process as claimed in claim 9, wherein component A is crystalline.

12. The process as claimed in claim 9, wherein component A is in sheet form or powder form.

13. The process as claimed in claim 9, wherein component A and component B differ in density, and the temperature of the dispersion is maintained so as to retard or prevent separation of the components.

14. The process of claim 9, wherein component A and component B differ in density, and the dispersion of components A and B comprises a solid phase alloy of A and B dispersed in liquid component B.

15. The process as claimed in claim 1, wherein the dispersion further comprises a thermal dye.

16. The process as claimed in claim 1, wherein component A has a melting point MpA, component B has a melting point MpB, and MpA is higher than MpB, and wherein homogenization forms an alloy having an eutectic which is different from MpB.

17. The process of claim 16, wherein the integral article is separated from the dispersion based on difference in melting point.

18. The process as claimed in claim 5, wherein the polymer alloy of component A/component B is polycaprolactone/poly(vinylchloride), polycaprolactone/Saran, polycaprolactone/bisphenol A polycarbonate, poly(vinyl methyl ether)/phenoxy, poly(ethylene oxide)/phenoxy, poly(ethylene oxide)/poly(acrylic acid), BPA polycarbonate/PHFA, or polystyrene/polyphenylene oxide.

19. The process as claimed in claim 7, wherein components A and B comprise bismuth and magnesium or aluminum and gallium.

20. A process for producing a homogenized, three-dimensional, integral object of components A and B, comprising the steps of:

a) providing a layer of liquid component B;

b) homogenizing components A and B by adding solid or liquid component A in an imagewise manner to a surface of the layer of liquid component B for forming an alloy layer of components A and B, which alloy layer hardens upon homogenization;

c) repeating steps a)-b) by applying each successive alloy layer of homogenized region onto the previous alloy layer, such that each new homogenized region becomes integral with the previous homogenized region to form the homogenized, three-dimensional, integral object.

21. The process as claimed in claim 20, wherein the imagewise addition of components is carried out by ink or powder jetting one component onto the previous layer.