Color or multi-material three-dimensional (3D) printing

• US 9,688,022 B2
• Filed: 10/28/2016
• Issued: 06/27/2017
• Est. Priority Date: 11/18/2013
• Status: Active Grant

• Current Assignee: San Draw Inc.
• Original Assignee: San Draw Inc.
• Inventors: Chang, Kai-Jui
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US15/337,344
• Publication Number:
  US 20170043533A1
• Time in Patent Office: 242 Days
• Field of Search: 264245, 264255, 264308, 264494
• CPC Class Codes: B01F 33/84 Mixing plants with mixing receptacles receiving material dispensed from several component receptacles, e.g. paint tins
• CPC Class Codes: B01F 35/7174 using pistons, plungers or syringes
• 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 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29C 67/0007 Manufacturing coloured articles not otherwise provided for, e.g. by colour change
• 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

Abstract

A three-dimensional (3D) continuous color printer includes one or more cartridges each with a building material stored therein, a mixer coupled to each cartridge, and a single printhead coupled to a mixer output, wherein the building material stored in the cartridge is transported to the mixer and the single print head to form a continuous color object.

Claims

1. A method for forming a three-dimensional object, comprising:

(a) providing at least two material cartridges that are in fluid communication with a mixer that is in fluid communication with a nozzle of a print head, wherein each material cartridge contains a building material;

(b) using building materials from said at least two material cartridges to generate a first mixture in said mixer;

(c) extruding said first mixture from said mixer through said nozzle towards a support to form a first layer of said first mixture adjacent to said support, wherein said first layer is part of said three-dimensional object;

(d) using building materials from said at least two material cartridges to generate a second mixture in said mixer; and

(e) extruding said second mixture from said mixer through said nozzle towards said support to form a second layer of said second mixture as part of said three-dimensional object, wherein at least a portion of said second layer is adjacent to at least a portion of said first layer,

wherein said print head is moveable with respect to said support, and

wherein said at least two material cartridges are fixed with respect to said support.

2. The method of claim 1, wherein said at least two material cartridges comprise building materials that are of different color, and wherein generation of said first mixture generates a third color of building materials.

3. The method of claim 1, wherein said at least two material cartridges comprise at least three material cartridges.

4. The method of claim 3, further comprising using building materials from said at least three material cartridges to generate said first mixture.

5. The method of claim 3, wherein said at least three material cartridges comprise at least four material cartridges, wherein a first material cartridge contains a building material that is of a first color, a second material cartridge contains a building material that is of a second color, a third material cartridge contains a building material that is of a third color, and a fourth material cartridge contains a building material that is of a fourth color, wherein said first color, second color, third color and fourth color are different.

6. The method of claim 1, wherein a building material in a given one of said material cartridges comprises a polymeric material.

7. The method of claim 1, wherein a building material in a given one of said material cartridges comprises a fluid or paste that is solidifiable upon contact with an initiating agent.

8. The method of claim 1, wherein a building material in a given one of said material cartridges comprises a crosslinking agent, initiator, accelerator, or any combination thereof.

9. The method of claim 1, wherein a given one of said building materials is in a liquid state.

10. The method of claim 1, wherein said first mixture is directed from said mixer at a constant flow rate.

11. The method of claim 1, wherein said first mixture and second mixture are generated continuously.

12. The method of claim 1, wherein said mixer is part of said print head.

13. The method of claim 1, wherein said generation of said first mixture is via in-line mixing or active mixing.

14. The method of claim 1, wherein (c) comprises (i) directing said first mixture from said mixer towards said support and (ii) radiating said first mixture adjacent to said support to form said first layer.

15. The method of claim 14, wherein (e) comprises (i) directing said second mixture from said mixer towards said support and (ii) radiating said second mixture adjacent to said support to form said second layer.

16. The method of claim 1, wherein said first layer is in accordance with a model design of said three-dimensional object.

17. The method of claim 16, wherein said model design is in a digital file.

18. The method of claim 1, wherein said first mixture is different than said second mixture.

19. The method of claim 1, wherein said first mixture is the same as said second mixture.

20. The method of claim 1, wherein said mixer is part of a pathway that is in fluid communication with said nozzle.