Process for fabrication of three-dimensional objects

• US 9,227,366 B2
• Filed: 10/26/2011
• Issued: 01/05/2016
• Est. Priority Date: 10/27/2010
• Status: Active Grant

• Current Assignee: Raisa Milkin & Eugene Giller 2017 Trust
• Original Assignee: File2Part, Inc.
• Inventors: Giller, Eugene
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US13/881,554
• Publication Number:
  US 20140162033A1
• Time in Patent Office: 1,532 Days
• Field of Search: 264/113, 264/308, 264/317, 264/401, 264/460, 264/461, 264/462, 264/463, 264/494, 264/496, 264/497, 264/255
• US Class Current: 1/1
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0855 using microwave
• CPC Class Codes: B29C 2035/0861 using radio frequency
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• 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 64/106 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 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/124 using layers of liquid which are selectively solidified
• CPC Class Codes: B29C 64/129 characterised by the energy source therefor, e.g. by global irradiation combined with a mask
• CPC Class Codes: B29C 64/135 the energy source being concentrated, e.g. scanning lasers or focused light sources
• 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: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2073/00 Use of other polymers having oxygen as the only hetero atom in the main chain, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2995/002 Coloured
• 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 70/00 : Materials specially adapted for additive manufacturing
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24901 : including coloring matter
• CPC Class Codes: Y10T 428/24917 : including metal layer

Abstract

A fabrication process and apparatus for producing three-dimensional objects (36) by depositing a first polymer layer, printing a first ink layer on to the first polymer layer (34), depositing a second polymer layer on to the first ink layer, and printing a second ink layer on to the second polymer layer. The deposition and printing steps may be repeated until a three-dimensional object (36) is formed. The inks used to form at least one of the first and second ink layers may include dyes or pigments so that the three-dimensional object may be a colored three-dimensional object.

Claims

1. A three-dimensional fabrication method comprising:

(a) extruding a first polymer layer;

(b) printing a first ink layer on to the first polymer layer;

(c) extruding a second polymer layer on to the first ink layer;

(d) printing a second ink layer on to the second polymer layer; and

(e) repeating steps (a)-(d) to form a three-dimensional object.

2. The three-dimensional fabrication method of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink comprising at least one of pigments, dyes, catalysts, plasticizers, or active ingredients.

3. The three-dimensional fabrication method of claim 1, wherein at least one of the first ink layer and the second ink layer includes a color ink.

4. The three-dimensional fabrication method of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink, and wherein the ink is a plasticizing ink or a releasable ink.

5. The three-dimensional fabrication method of claim 1, wherein at least one of the first ink layer and the second ink layer and at least one of the first polymer layer and the second polymer layer are treated with an energy source during fabrication of the three-dimensional object.

6. The three-dimensional fabrication method of claim 1, wherein the first ink layer and the second ink layer provide different surface properties to the three-dimensional object.

7. The three-dimensional fabrication method of claim 1, wherein a support structure is formed adjacent to the three-dimensional object during the three-dimensional fabrication process, and wherein a releasable ink layer is printed between the three-dimensional object and the support structure.

8. The three-dimensional fabrication method of claim 7, wherein the support structure is formed from a polymeric material, and wherein the support structure polymeric material is similar to a polymeric material used to form the three-dimensional object.

9. The three-dimensional fabrication method of claim 7, wherein the support structure is formed from a polymeric material, and wherein the support structure polymeric material is the same as a polymeric material used to form the three-dimensional object.

10. The three-dimensional fabrication method of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink that provides increased flexibility to the three-dimensional object.

11. The three-dimensional fabrication method of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink that creates a smooth surface on the three-dimensional object.

12. The three-dimensional fabrication method of claim 1, wherein at least one of the first ink layer and the second ink layer includes an ink selected based on an ink solubility parameter in relation to a polymer solubility parameter.

13. A three-dimensional fabrication method comprising:

(a) extruding a first polymer layer;

(b) printing a first ink layer on to the first polymer layer;

(c) extruding a second polymer layer on to the first ink layer;

(d) printing a second ink layer on to the second polymer layer; and

(e) repeating steps (a)-(d) to form a three-dimensional object,

wherein at least one of the first ink layer and the second ink layer includes a plasticizing ink selected based on an ink solubility parameter in relation to a polymer solubility parameter.