Machinable positive image model material for shape deposition manufacturing

• US 6,342,541 B1
• Filed: 12/08/1999
• Issued: 01/29/2002
• Est. Priority Date: 12/08/1999
• Status: Expired due to Term

• Current Assignee: Advanced Ceramics Research LLC
• Original Assignee: Advanced Ceramics Research, Inc. (Rtx Corporation)
• Inventors: Lombardi, John Lang, Artz, Gregory John
• Primary Examiner(s): Seidleck, James J.
• Assistant Examiner(s): MCCLENDON, SANZA L
• Application Number:
  US09/456,865
• Time in Patent Office: 783 Days
• Field of Search: 522/88, 522/89, 522/114, 522/116, 522/126, 522/71, 522/120, 522/121, 106/38.2, 430/269, 430/280.1, 430/281.1, 430/286.1, 430/287.1, 525/242, 527/312, 527/313, 527/314, 527/315, 264/401
• US Class Current: 522/88
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29K 2033/26 Polymers of acrylamide or methacrylamide
• CPC Class Codes: B29K 2039/06 Polymers of N-vinyl-pyrrolidones
• CPC Class Codes: B29K 2091/00 Use of waxes as moulding material
• CPC Class Codes: B29K 2995/0059 Degradable

Abstract

A manufacturing method comprising the steps of forming at first solidified wax layer of a desired shape, depositing onto the first solidified wax layer at least one layer of a liquid resin formulation, solidifying the layer of liquid resin formulation, depositing a second wax layer on to the combination of the first solidified wax layer and the layer of solidified resin formulation, solidifying the second wax layer, and separating the solidified resin formulation from first and second wax layers. Preferably, the resin formulation comprises at least one monofunctional water soluble vinyl or acrylic monomer in combination with a low molecular weight aliphatic polymer having acrylic or methacrylic acid functionality. The solidified wax and resin formulation layers can be machined as may be desired to form mold of a given shape comprising wax layers when the layer of formulation is separated from the wax layers.

Claims

1. A liquid resin formulation comprising at least one monofunctional water soluble vinyl or acrylic monomer in combination with a low molecular weight aliphatic polymer having acrylic or methacrylic acid functionality, and further comprising a sugar.

2. The liquid resin formulation of claim 1 wherein the sugar comprises confectioner'"'"'s powdered sugar.

3. A liquid resin formulation comprising at least one monofunctional water soluble vinyl or acrylic monomer in combination with a low molecular weight aliphatic polymer having acrylic or methacrylic acid functionality, wherein the low molecular weight aliphatic polymer having acrylic or methacrylic acid functionality comprises polyethylene co-acrylic acid, polystyrene co-acrylic acid, or polyalkylacrylate co-acrylic acid.