Support material and applications thereof

• US 8,460,451 B2
• Filed: 02/23/2011
• Issued: 06/11/2013
• Est. Priority Date: 02/23/2011
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Xu, Pingyong, Moussa, Khalil, Stockwell, John
• Primary Examiner(s): Brunsman, David M
• Application Number:
  US13/032,936
• Publication Number:
  US 20120213976A1
• Time in Patent Office: 839 Days
• Field of Search: 106/31.61, 106270-272
• US Class Current: 106/270
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0833 using actinic light
• CPC Class Codes: B29C 2035/0838 using laser
• CPC Class Codes: B29C 33/40 Plastics, e.g. foam or rubber
• CPC Class Codes: B29C 33/52 soluble or fusible in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• 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: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2891/00 Use of waxes as mould material
• CPC Class Codes: B29K 2995/0062 water-soluble
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B41M 5/508 Supports
• CPC Class Codes: C08K 5/05 Alcohols; Metal alcoholates
• CPC Class Codes: C08L 91/06 Waxes
• CPC Class Codes: C09D 191/06 Waxes
• CPC Class Codes: C09D 7/43 : Thickening agents
• CPC Class Codes: C09D 7/63 : organic
• CPC Class Codes: C09K 5/066 : Cooling mixtures; De-icing compositions
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

In one aspect, support materials operable for use in 3D printing systems are described herein. In some embodiments, a support material comprises a wax component comprising at least one ethoxylated fatty alcohol and a viscosity modifying agent, wherein the support material is water dispersible. In some embodiments, the wax component comprises a mixture of at least one fatty alcohol and at least one ethoxylated fatty alcohol.

Claims

1. A support material for use in a three-dimensional printing system comprising:

a wax component comprising at least one ethoxylated fatty alcohol; and

a viscosity modifying component comprising at least one lactone, wherein the support material is water dispersible and wherein the lactone is at least partially polymerized.

2. The support material of claim 1, wherein the wax component is present in an amount ranging from about 50 weight percent to about 95 weight percent.

3. The support material of claim 1, wherein the at least one ethoxylated fatty alcohol has a formula CH₃—

(CH₂)_m—

(O—

CH₂—

CH₂—

)_n—

OH, wherein n is an integer from 2 to 100 and m is an integer from 10 to 20.

4. The support material of claim 1, wherein the wax component comprises a mixture of at least one fatty alcohol and at least one ethoxylated fatty alcohol.

5. The support material of claim 1, wherein the viscosity modifying component further comprises one or more ethoxylated fatty alcohols.

6. The support material of claim 1 having a melting point ranging from about 45°

C. to about 70°

C.

7. The support material of claim 1 having a melting point ranging from about 50°

C. to about 65°

C.

8. The support material of claim 1 having a freezing point ranging from about 47°

C. to about 52°

C.

9. The support material of claim 1, wherein the support material is non-UV curable.

10. A support material for use in a three-dimensional printing system comprising:

a wax component comprising at least one ethoxylated fatty alcohol; and

a viscosity modifying component comprising at least one lactone, wherein the support material is water dispersible and wherein the at least one lactone comprises α

-acetolactone, β

-propiolactone, γ

-butyrolactone, δ

-valerolactone or ε

-caprolactone or mixtures thereof.

11. A support material for use in a three-dimensional printing system comprising:

a wax component comprising a plurality of ethoxylated fatty alcohols; and

a viscosity modifying component, wherein the support material is water dispersible and wherein the plurality of ethoxylated fatty alcohols comprise one or more ethoxylated fatty alcohols of the formula CH₃—

(CH₂)_m—

(O—

CH₂—

CH₂—

)_n—

OH, wherein n is an integer from 2 to 100 and m is an integer from 10 to 20 , and a sorbitan monooctadecanoate poly(oxy-1,2-ethanediyl).

12. A support material for use in a three-dimensional printing system comprising:

a wax component comprising at least one ethoxylated fatty alcohol;

a viscosity modifying component; and

a phase change agent comprising one or more polyurethane waxes,

wherein the support material is water dispersible.

13. The support material of claim 12, wherein the phase change agent is present in an amount ranging from about 0.1 weight percent to about 5 weight percent.