Method and a system for solid freeform fabricating using non-reactive powder

• US 7,120,512 B2
• Filed: 08/25/2003
• Issued: 10/10/2006
• Est. Priority Date: 08/25/2003
• Status: Active Grant

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Lambright, Terry M., Kramer, Laura, Kasperchik, Vladek P, Boyd, Melissa D.
• Primary Examiner(s): Picard, Leo
• Assistant Examiner(s): KASENGE, CHARLES R
• Application Number:
  US10/648,122
• Publication Number:
  US 20050049739A1
• Time in Patent Office: 1,142 Days
• Field of Search: 700/97, 700/98, 700/117, 700/118, 700/119, 700/182, 700/198, 700/120, 430/14, 430/15, 430/18, 430/22, 430/124, 156/273.1, 425/174.8, 264/113, 264/308, 264/401, 264/463
• US Class Current: 700/119
• 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: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing

Abstract

A method for creating a three-dimensional solid freeform fabrication object with non-reactive powder includes spreading a non-reactive powder on a substrate, selectively dispensing a reactive resin onto the non-reactive powder forming a mixture of reactive resin and non-reactive powder, wherein the selective dispensing of the reactive resin defines the three-dimensional object, and curing the reactive resin thereby encapsulating the non-reactive powder.

Claims

1. A method for creating a three-dimensional solid freeform fabrication object with non-reactive powder comprising:

spreading a non-reactive powder on a substrate;

heating a reactive resin to a temperature of about 40 to 200 degrees Celsius (C);

selectively dispensing said heated reactive resin onto said non-reactive powder, forming a mixture of reactive resin and non-reactive powder, wherein said mixture defines said three-dimensional object; and

curing said reactive resin thereby encapsulating said non-reactive powder.

2. The method of claim 1, wherein said reactive resin comprises an ultraviolet (UV) curable resin.

3. The method of claim 1, further comprising dispensing said heated reactive resin directly onto said non-reactive powder on said substrate.

4. The method of claim 1, further comprising applying ultrasonic energy to said mixture of reactive resin and non-reactive powder.

5. The method of claim 1, wherein curing said reactive resin further comprises:

partially curing said reactive resin;

applying at least one other layer of non-reactive powder and selectively dispensed reactive resin; and

fully curing said reactive resin after said at least one other layer is formed to promote adhesion between layers of said object.

6. A solid freeform fabrication system for producing a three-dimensional object using non-reactive powder comprising:

a powder spreading system configured to spread a specified quantity of non-reactive powder to form a layer of said powder on a substrate;

a dispensing system adapted to selectively dispense both components of a two-part reactive resin onto said layer of non-reactive powder; and

a computing device coupled to and configured to control said dispensing system and said powder spreading system;

wherein said dispensing system comprises an inkjet dispenser.

7. The solid freeform fabrication system of claim 6, wherein said inkjet dispenser comprises one of a thermal inkjet dispenser, a continuous inkjet dispenser, or a piezoelectric inkjet dispenser.

8. The solid freeform fabrication system of claim 6, wherein said inkjet dispenser comprises a plurality of ejection orifices configured to selectively eject both components of said two-part reactive resin.

9. A solid freeform fabrication system for producing a three-dimensional object using non-reactive powder comprising:

spreading means for spreading successive layers of said non-reactive powder;

dispensing means for dispensing a reactive resin onto said non-reactive powder;

curing means for curing said reactive resin, wherein said curing means only partially cures a layer of reactive resin until at least one additional layer of non-reactive powder and selectively-dispensed reactive resin have been formed, said reactive resin then being fully cured so as to promote adhesion between layers of said object; and

controlling means for controlling said spreading means, said dispensing means, and said curing means.

10. The solid freeform fabrication system of claim 9, wherein said spreading means comprises one of a blade or a mechanical roller.

11. The solid freeform fabrication system of claim 9, wherein said dispensing means comprises a thermal inkjet dispenser.

12. The solid freeform fabrication system of claim 9, wherein said dispensing means comprises one of a piezoelectric inkjet dispenser or a continuous inkjet dispenser.

13. The solid freeform fabrication system of claim 9, wherein said curing means comprises a heater.

14. The solid freeform fabrication system of claim 9, wherein said curing means comprises a UV radiation applicator.

15. The solid freeform fabrication system of claim 9, wherein said controlling means comprises a computer.

16. A method for creating three-dimensional solid freeform fabrication object with non-reactive powder comprising:

spreading a non-reactive powder on a substrate;

selectively dispensing a reactive resin onto said non-reactive powder, forming a mixture of reactive resin and non-reactive powder, wherein said mixture defines said three-dimensional object;

applying ultrasonic energy to said mixture of reactive resin and non-reactive powder; and

curing said reactive resin thereby encapsulating said non-reactive powder;

wherein curing said reactive resin further comprises;

partially curing said reactive resin;

applying at least one other layer of non-reactive powder and selectively-dispensed reactive resin; and

fully curing said reactive resin after said at least one other layer is formed to promote adhesion between layers of said object.

17. A method for creating a three-dimensional solid freeform fabrication object with non-reactive powder comprising:

spreading a non-reactive powder on a substrate;

selectively dispensing a reactive resin onto said non-reactive powder, forming a mixture of reactive resin and non-reactive powder, wherein said mixture defines said three-dimensional object;

partially curing said reactive resin;

applying at least one other layer of non-reactive powder and selectively-dispensed reactive resin; and

fully curing said reactive resin after said at least one other layer is formed to promote adhesion between layers of said object.

18. A system for fabricating a three-dimensional solid freeform fabrication object with non-reactive powder comprising:

a system for spreading a non-reactive powder on a substrate;

an inkjet dispenser for selectively dispensing a reactive resin onto said non-reactive powder, forming a mixture of reactive resin and non-reactive powder, wherein said mixture defines said three-dimensional object; and

a curing system for curing said reactive resin thereby encapsulating said non-reactive powder.

19. The system of claim 18, wherein said curing system comprises an ultraviolet light source.

20. The system of claim 18, further comprising a system for applying ultrasonic energy to said mixture prior to curing.