Self-hardening material and process for layerwise formation of models
First Claim
Patent Images
1. A process comprising the steps of:
- a. applying at least one particulate material in the form of a loose powder; and
b. separately applying a bonding agent over a portion of the at least one particulate material for selectively bonding the at least one particulate material;
wherein a setting time is at least several times as long as an application time of a layer of the at least one particulate material;
wherein the process is a process for layerwise construction of a three-dimensional component in a bed of the loose powderwherein the process includes a step of hardening a layer of the three-dimensional component after applying at least 20 subsequent layers.
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Abstract
The invention relates to a self-hardening material for layerwise construction of three-dimensional components, whereby the material comprises at least one particulate material and a separately applied bonding agent for bonding the particulate material, and has a setting time which is at least several times as long as the application time of a particulate layer.
201 Citations
28 Claims
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1. A process comprising the steps of:
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a. applying at least one particulate material in the form of a loose powder; and b. separately applying a bonding agent over a portion of the at least one particulate material for selectively bonding the at least one particulate material; wherein a setting time is at least several times as long as an application time of a layer of the at least one particulate material; wherein the process is a process for layerwise construction of a three-dimensional component in a bed of the loose powder wherein the process includes a step of hardening a layer of the three-dimensional component after applying at least 20 subsequent layers. - View Dependent Claims (2, 3, 4, 5, 6, 9, 10, 11, 12, 13, 16, 17, 18, 20, 21, 24, 25, 26, 27)
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7. A process comprising the steps of:
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a. applying at least one particulate material in the form of a loose powder; and b. separately applying a bonding agent over a portion of the at least one particulate material for selectively bonding the at least one particulate material; wherein a setting time is at least several times as long as an application time of a layer of the at least one particulate material; wherein the process is a process for layerwise construction of a three-dimensional component in a bed of the loose powder; and wherein the bonding agent contains at least one component selected from the group consisting of an acrylate, a methacrylate and a sterol.
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8. A process comprising the steps of:
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a. applying at least one particulate material in the form of a loose powder; and b. separately applying a bonding agent over a portion of the at least one particulate material for selectively bonding the at least one particulate material;
wherein a setting time is at least several times as long as an application time of a layer of the at least one particulate material;
wherein the process is a process for layerwise construction of a three-dimensional component in a bed of the loose powder; andwherein the at least one particulate material includes polymethylmethacrylate. - View Dependent Claims (14, 15)
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19. A process comprising the steps of:
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applying a first layer of a self-hardening material for printing a three-dimensional component; applying a second layer of the self-hardening material for printing the three- dimensional component, and setting the first layer after applying the second layer; wherein the second layer is applied on top of the first layer while the first layer is not yet hardened, and wherein the first layer and the second layer shrink by the same amount and at the same time;
the first layer and the second layer each include a layer of a particulate material to which a bonding agent is applied separately;wherein the particulate material includes polymethylmethacrylate, polyethylmetracrylate, ABS, PC-ABS, PA, PBT, a metal, glass, or carbon fiber, and the particulate material is in the form of a loose powder suitable for applying in a layerwise fashion and forming a powder bed; and
the bonding agent includes a polymerizable monomer and is a printable liquid suitable for applying over the particulate material; anda setting time of the self-hardening material of the first layer is at least 20 times as long as an application time of the first layer.
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22. A process comprising the steps of:
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a. applying at least one particulate material in the form of a loose powder; and b. separately applying a bonding agent over a portion of the at least one particulate material for selectively bonding the at least one particulate material; wherein a setting time is at least several times as long as an application time of a layer of the at least one particulate material; wherein the process is a process for layerwise construction of a three-dimensional component in a bed of the loose powder; and wherein the three-dimensional component is constructed over a build platform having a porous surface.
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23. A process comprising the steps of:
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a. applying at least one particulate material in the form of a loose powder; and b. separately applying a bonding agent over a portion of the at least one particulate material for selectively bonding the at least one particulate material; wherein a setting time is at least several times as long as an application time of a layer of the at least one particulate material; wherein the process is a process for layerwise construction of a three-dimensional component in a bed of the loose powder; and the three-dimensional component cures at about room temperature.
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28. A method for a layered construction of three-dimensional parts, wherein a particulate material and a binding agent are applied in layers for self-curing of the particulate material, wherein a solidifying reaction is delayed by a suitable selection of a chemical composition of the particulate material and the binding agent and/or of ambient physical conditions such that solidification and shrinkage acts on the layered construction of three-dimensional parts no sooner than after application of 20 layers.
Specification