Compositions and methods for selective deposition modeling

• US 8,975,352 B2
• Filed: 11/18/2013
• Issued: 03/10/2015
• 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:
  US14/082,471
• Publication Number:
  US 20140076499A1
• Time in Patent Office: 477 Days
• Field of Search: 156/703, 526/348
• US Class Current: 526/348
• 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 object 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 method of separating a three-dimensional object produced with build material from a support material used to support the build material during the production of the three-dimensional object, the method comprising:

positioning the three-dimensional object and the support material in a bath of polar solvent;

agitating the bath of polar solvent with respect to the support material in the bath; and

removing a white residue from the three-dimensional object.

2. The method of claim 1, wherein removing the white residue comprises removing the object from the bath of polar solvent and rinsing the object with a solution comprising about 30% glycerin-alcohol.

3. The method of claim 1, wherein the bath of polar solvent comprises one or more of poly(propylene)glycol, ethanol, and isopropyl alcohol.

5. The method of claim 3, wherein the bath of polar solvent comprises 100% isopropyl alcohol.

8. The method of claim 1, wherein the bath of polar solvent comprises 91% isopropyl alcohol.

9. The method of claim 1, wherein the temperature of the polar solvent is controlled to be between about 35°

C. and about 50°

C.

10. The method of claim 1, wherein the temperature of the polar solvent is controlled to be between about 42°

C. and about 50°

C.

4. A method of separating a three-dimensional object produced with build material from a support material used to support the build material during the production of the three-dimensional object, the method comprising:

positioning the three-dimensional object and the support material in a bath of polar solvent; and

agitating the bath of polar solvent with respect to the support material in the bath,

wherein the bath of polar solvent comprises 91% isopropyl alcohol.

6. A method of separating a three-dimensional object produced with build material from a support material used to support the build material during the production of the three-dimensional object, the method comprising:

positioning the three-dimensional object and the support material in a bath of polar solvent; and

agitating the bath of polar solvent with respect to the support material in the bath,

wherein the temperature of the polar solvent is controlled to be between about 35°

C. and about 50°

C.

7. A method of separating a three-dimensional object produced with build material from a support material used to support the build material during the production of the three-dimensional object, the method comprising:

positioning the three-dimensional object and the support material in a bath of polar solvent; and

agitating the bath of polar solvent with respect to the support material in the bath,

wherein the temperature of the polar solvent is controlled to be between about 42°

C. and about 50°

C.