Compositions and methods for selective deposition modeling

• US 8,642,692 B1
• Filed: 09/30/2013
• Issued: 02/04/2014
• Est. Priority Date: 05/12/2009
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Inventors: Stockwell, John, Xu, Pingyong
• Primary Examiner(s): CHEUNG, WILLIAM K
• Application Number:
  US14/041,411
• Publication Number:
  US 20140027950A1
• Time in Patent Office: 127 Days
• Field of Search: 524/478, 524/480, 524/489, 524/491
• US Class Current: 524/478
• 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 71/0009 using liquids, e.g. solvents, swelling agents spectacle cases, e.g. for cleaning contact lenses A45C11/04; disinfecting or sterilising contact lenses A61L12/00, using liquid substances A61L2/20; cleaning involving the use of liquid in general B08B3/00; for hydrating contact lenses B29D11/00067
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B33Y 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• CPC Class Codes: C08L 91/08 Mineral waxes
• CPC Class Codes: Y10T 156/1111 Using solvent during delaminating [e.g., water dissolving adhesive at bonding face during delamination, etc.]

Abstract

There is provided compositions and methods for producing three-dimensional objects by selective deposition modeling with a polar build material and a non-polar support material. The build material comprises a hydrocarbon wax material and a viscosity modifier, and the support material comprises a hydrocarbon alcohol wax material and a viscosity modifier. After the selective deposition modeling process has been completed, the of can be placed in a bath of polar solvent to remove the support material. The particular materials provided herein, and the post-processing methods associated therewith, provide for improved part quality of the three-dimensional object and for improved post-processing techniques. The three-dimensional objects can subsequently be used in a number of applications, such as patterns for investment casting.

Claims

1. A combination of compositions used to produce a three-dimensional object with a selective deposition modeling apparatus, the combination comprising:

(a) a build material comprising;

(i) a build hydrocarbon wax material, wherein the build hydrocarbon wax material comprises between 75% and 85% by weight of the build material, and

(ii) at least one build viscosity modifier defining a hydrocarbon resin free of oxygen, wherein the build viscosity modifier comprises between 15% and 25% by weight of the build material; and

(b) a support material comprising;

(i) a support hydrocarbon alcohol wax material, wherein the support hydrocarbon alcohol wax material comprises between 60% and 68% by weight of the support material, and

(ii) at least one support viscosity modifier defining a hydrogenated rosin, wherein the support viscosity modifier comprises between 32% and 40%, by weight of the support material.

2. The combination of compositions of claim 1, wherein the build hydrocarbon wax material comprises a paraffin wax.

3. The combination of compositions of claim 1, wherein the build viscosity modifier comprises a hydrogenated hydrocarbon resin.

4. The combination of compositions of claim 1, wherein the build hydrocarbon wax material comprises about 81% by weight of the build material and the build viscosity modifier comprises about 19% by weight of the build material.

5. The combination of compositions of claim 1, wherein the support hydrocarbon alcohol wax material comprises at least one of octadecanol and hexadecanol.

6. The combination of compositions of claim 1, wherein the support viscosity modifier defines a hydrogenated rosin having an acid number between about 100 and about 150.

7. The combination of compositions of claim 1, wherein the support hydrocarbon alcohol wax material comprises about 65% by weight of the support material and the support.