Solid free-form fabrication of three-dimensional objects

• US 7,381,360 B2
• Filed: 11/03/2003
• Issued: 06/03/2008
• Est. Priority Date: 11/03/2003
• Status: Active Grant

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Farr, Isaac, Oriakhi, Christopher
• Primary Examiner(s): Tentoni; Leo B
• Application Number:
  US10/700,603
• Publication Number:
  US 20050093194A1
• Time in Patent Office: 1,674 Days
• Field of Search: 264/113, 264/494, 264/463
• US Class Current: 264/463
• CPC Class Codes: B28B 1/00 Producing shaped prefabricated articles from the material using presses B28B3/00; shaping on moving conveyors B28B5/00; producing tubular articles B28B21/00 ; producing articles with embedded elements B28B23/00
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• 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
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/254 Polymeric or resinous material

Abstract

The present invention is drawn toward compositions, methods, and systems for solid free-form fabrication of three-dimensional objects. In one embodiment, a system for solid free-form fabrication of three-dimensional objects can comprise a particulate composition, a substrate configured for supporting at least a layer of the particulate composition in a defined region, and a liquid phase binder configured for being jetted in the defined region to polymerize at least a portion of the particulate composition to form a polymeric cement. Using this system in a layer by layer deposition process, three-dimensional objects can be formed. The particulate composition can include from 70 wt % to 99.9 wt % of polymeric particulates, and from 0.1 wt % to 10 wt % of a polymerization initiator. The liquid phase binder can include from 70 wt % to 90 wt % of polymerizable monomers and from 0.1 wt % to 10 wt % of a polymerization accelerator.

Claims

1. A method of fabricating a three-dimensional object, comprising:

a) depositing a particulate composition in a defined region, said particulate composition including;

i) from 70 wt % to 99.9 wt % of polymeric particulates, and

ii) from 0.1 wt % to 10 wt % of a polymerization initiator;

b) jetting a liquid phase binder onto a predetermined area of the particulate composition to form a layer of polymeric cement in the predetermined area, said liquid phase binder including;

i) from 70 wt % to 90 wt % of polymerizable monomers, and

ii) from 0.1 wt % to 10 wt % of a polymerization accelerator;

c) repeating steps a) and b) such that multiple layers of polymeric cement are formed that are bound to one another.

2. A method as in claim 1, wherein the particulate composition further comprises from 0.1 wt % to 20 wt % of nanoparticle fillers.

3. A method as in claim 1, wherein the polymeric particulates include a member selected from the group consisting of acrylate particulates, methacrylate particulates, siloxane particulates, and combinations thereof.

4. A method as in claim 3, wherein the polymeric particulates include polymethylmethacrylate homopolymers or copolymers having a weight average molecular weight from 20,000 Mw to 1,000,000 Mw.

5. A method as in claim 1, wherein the polymerization initiator includes a member selected from the group consisting of a free radical initiator base and an organic peroxide.

6. A method as in claim 5, wherein the polymerization initiator includes dibenzoyl peroxide.

7. A method as in claim 1, wherein the liquid phase binder further comprises a liquid stabilizer.

8. A method as in claim 1, wherein the polymerizable monomers include a member selected from the group consisting of acrylate monomers, methacrylate monomers, and combinations thereof.

9. A method as in claim 8, wherein the polymerizable monomers include methylmethacrylate monomers.

10. A method as in claim 1, wherein the polymerization accelerator includes an amine.

11. A method as in claim 1, wherein the polymerization accelerator includes N,N-dimethyl-p-toluidine.

12. A method as in claim 1, wherein the polymerization accelerator includes dihydroxyethyl-p-toluidine.

13. A method as in claim 1, wherein the liquid phase binder further includes a colorant.

14. A method as in claim 1, further comprising the step of removing a portion of the particulate composition that does not form the polymeric cement.

15. A method as in claim 1, wherein the particulate composition and the liquid phase binder are reacted in the presence of UV energy.

16. A method of fabricating a three-dimensional object, comprising:

a) depositing a particulate composition in a defined region, said particulate composition including;

i) polymeric particulates, wherein the polymeric particulates include a member selected from the group consisting of acrylate particulates, methacrylate particulates, siloxane particulates, and combinations thereof, and

ii) a polymerization initiator, wherein the polymerization initiator includes a member selected from the group consisting of a free radical initiator base and an organic peroxide;

b) jetting a liquid phase binder onto a predetermined area of the particulate composition to form a layer of polymeric cement in the predetermined area, said liquid phase binder including;

i) polymerizable monomers, and

ii) a polymerization accelerator, wherein the polymerization accelerator is selected from an amine, N,N-dimethyl-p-toluidine, and dihydroxyethyl-p-toluid me;

c) repeating steps a) and b) such that multiple layers of polymeric cement are formed that are bound to one another.