System and method for printing and supporting three dimensional objects

• US 7,364,686 B2
• Filed: 11/20/2003
• Issued: 04/29/2008
• Est. Priority Date: 03/21/2001
• Status: Expired due to Term

• Current Assignee: Stratasys Incorporated
• Original Assignee: Objet Geometries
• Inventors: Miller, Gershon, Kritchman, Eli, Gothait, Hanan
• Primary Examiner(s): Tentoni; Leo B.
• Application Number:
  US10/716,426
• Publication Number:
  US 20040207124A1
• Time in Patent Office: 1,622 Days
• Field of Search: 264/308, 264/401, 264/497, 264/494
• US Class Current: 264/494
• CPC Class Codes: B29C 35/04 using liquids, gas or steam
• CPC Class Codes: B29C 35/08 by wave energy or particle radiation B29C64/00, B29C71/04 take precedence
• CPC Class Codes: B29C 37/0067 Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other separating agents B29C33/60
• 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 70/68 by incorporating or moulding on preformed parts, e.g. inserts or layers , e.g. foam blocks mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/20 Post-treatment, e.g. curing, coating or polishing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 29/49982 Coating
• CPC Class Codes: Y10T 29/49993 Filling of opening

Abstract

A method for printing and supporting a three-dimensional (3-D) object is provided. The method of printing can include dispensing a first interface material for the construction of the three-dimensional object, dispensing a second interface material to form a support structure for supporting the three-dimensional object and dispensing a third interface material which may be used to separate the support structure from the 3-D object Disclosed also a method for producing a 3-D model containing various kinds of inserts.

Claims

1. A method for building three-dimensional objects, said method comprising:

dispensing a first material to form at least one three-dimensional object and at least part of a support structure; and

dispensing a second material to form at least another part of the support structure and a release layer between said three-dimensional object and said support structure,

wherein said support structure comprises at least one pillar of said first material surrounded by said second material, said pillar not being in contact with said three-dimensional object.

2. The method of claim 1 wherein at least said first material is a photopolymer and at least the three-dimensional object is formed after being irradiated by electromagnetic radiation.

3. The method of claim 1 wherein said second material comprises a photopolymer and the support structure is formed after being irradiated by electromagnetic radiation.

4. The method of claim 1 wherein said release layer comprises a photopolymer and is formed after being irradiated by electromagnetic radiation.

5. The method of claim 1 comprising separating said support structure and release layer from said three-dimensional object.

6. The method according to claim 5 comprising subjecting said support structure and release layer to a solvent causing the support structure and release layer to weaken.

7. The method according to claim 1, where said support structure further comprises a container formed of said first material, said container being capable of confining said second material.

8. The method according to claim 1, further comprising constructing at least one connecting membrane of said first material attached to at least one said pillar.

14. The method of claim 1, wherein said support structure comprises a plurality of pillars which are not in contact with said three-dimensional object, said pillars being surrounded by said support material and separated from said three-dimensional object by said release layer.

15. The method according to claim 14, further comprising constructing membranes of said first material between said pillars.

16. The method according to claim 1, wherein said at least one pillar comprises a plurality of layers and wherein a topmost layer of said at least one pillar is adjacent to the release layer being between said three-dimensional object and said support structure.

17. The method of claim 1, wherein said second material is at least partly liquid or paste.

9. A method for building three-dimensional objects, said method comprising:

dispensing a curable build material to form a three-dimensional object;

dispensing a support material to form at least part of a support structure; and

selectively dispensing the build material to form at least another part of the support structure, said other part comprising at least a container capable of retaining said support material, said support material being at least partly liquid or paste.

10. The method according to claim 9, wherein said container comprises a base, a plurality of walls and an open top.

11. The method according to claim 10, wherein said container comprises at least one nib projecting from at least one of said walls, wherein said at least one nib is capable of restraining the movement of the three-dimensional object.

12. The method according to claim 9, wherein said support structure further comprises at least one pillar of said build material, said support material and said at least one pillar being retained within said container.

13. The method according to claim 9, wherein each of said build material, support material and container arc dispensed in layers.