Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L91/00—Compositions of oils, fats or waxes; Compositions of derivatives thereof
  • C08L91/06—Waxes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
  • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• • B29C67/0092—
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y10/00—Processes of additive manufacturing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
  • B33Y40/20—Post-treatment, e.g. curing, coating or polishing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y70/00—Materials specially adapted for additive manufacturing
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/04—Homopolymers or copolymers of ethene
  • C08L23/06—Polyethene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
  • B29K2023/04—Polymers of ethylene
  • B29K2023/06—PE, i.e. polyethylene
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2091/00—Use of waxes as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B33—ADDITIVE MANUFACTURING TECHNOLOGY
  • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
  • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling

Definitions

• the present invention relates to support materials and, in particular, to water dispersible support materials for use with three-dimensional (3D) printing systems.
• 3D printers such as the ProJetTM 3D Printers manufactured by 3D Systems of Rock Hill, S.C., use inks, which are also known as build materials, that are jetted through a print head as a liquid to form various 3D objects or parts.
• inks which are also known as build materials
• Other 3D printing systems also use an ink or build material that is jetted through a print head.
• the build material is solid at ambient temperatures and converts to liquid at elevated jetting temperatures. In other instances, the build material is liquid at ambient temperatures.
• production of a 3D part in a 3D printing system often requires the use of a support material in conjunction with the build material.
• the support material is also jetted through a print head as a liquid and then subsequently solidified.
• the support material is subsequently removed to provide the finished 3D part.
• Removal of the support material can be administered through several processes, including heating the support material to a temperature above its melting point in conjunction with the use of a suitable organic carrier to sufficiently remove the support material from the build material.
• the organic carrier deposits an undesirable oily residue on the completed 3D part.
• elevated temperatures in addition to a suitable organic carrier, in some situations, can compromise the mechanical integrity of the finished 3D part resulting in part deformation or failure.
• a soap or detergent may be used to remove the support material from a 3D part, including at elevated temperatures.
• support materials for use with a 3D printer are described herein which, in some embodiments, may offer one or more advantages over prior support materials.
• a support material described herein provides good adhesion to a build material and/or a print pad or other 3D printing substrate.
• a support material described herein can also be water dispersible or water soluble, including at room temperature or near room temperature. Further, in some cases, a support material described herein can be removed from a finished part without the use of a soap or detergent.
• a support material for use in a 3D printing system described herein comprises a phase change wax component and an ethoxylated polyethylene having the formula H—(CH 2 ) m —(OCH 2 CH 2 ) n —OH, wherein m is an integer from 22 to 60 or from 30 to 40, and n is an integer from 2 to 200 or from 10 to 100.
• the phase change wax component and the ethoxylated polyethylene are each present in the support material in an amount of about 20-80% by weight or 40-60% by weight, based on the total weight of the support material.
• the phase change wax component of a support material described herein comprises a ketone wax, an ester wax, an alcohol wax, an amide wax, a urethane wax, or a mixture or combination thereof.
• a support material described herein further comprises about 2-30% by weight tackifier, based on the total weight of the support material.
• the tackifier in some cases, can comprise a rosin ester, a rosin alcohol, or a mixture or combination thereof.
• a support material described herein further comprises up to about 10% by weight inhibitor and/or stabilizing agent.
• a support material described herein can be non-curable.
• compositions are described herein.
• a composition described herein comprises a three-dimensionally printed article comprising a build material and a support material, the support material comprising a support material described above.
• the support material comprises a phase change wax component and an ethoxylated polyethylene having the formula H—(CH 2 ) m —(OCH 2 CH 2 ) n —OH, wherein m and n are integers having the values described above.
• a method of printing a 3D article described herein comprises selectively depositing layers of a fluid build material to form the 3D article on a substrate and supporting at least one of the layers of the build material with a support material, the support material comprising a support material described above.
• the support material comprises a wax component and an ethoxylated polyethylene having the formula H—(CH 2 ) m —(OCH 2 CH 2 ) n —OH, wherein m is an integer from 22 to 60 and n is an integer from 2 to 200.
• the layers of the build material are deposited according to an image of the 3D article in a computer readable format, such as a computer aided design (CAD) format.
• a method described herein further comprises curing the build material.
• a method described herein further comprises removing the support material from the build material by contacting the support material with water, including water at or near room temperature.
• the phrase “up to” is used in connection with an amount or quantity, it is to be understood that the amount is at least a detectable amount or quantity.
• a material present in an amount “up to” a specified amount can be present from a detectable amount and up to and including the specified amount.
• three-dimensional printing system generally describe various solid freeform fabrication techniques for making three-dimensional articles or objects by selective deposition, jetting, fused deposition modeling, multijet modeling, and other techniques now known in the art or that may be known in the future that use a build material or ink to fabricate three-dimensional objects, parts, or articles.
• a support material described herein comprises a phase change wax component and an ethoxylated polyethylene having the formula H—(CH 2 ) m —(OCH 2 CH 2 ) n —OH, wherein m is an integer from 22 to 60 and n is an integer from 2 to 200.
• a support material described herein further comprises a tackifier.
• a support material described herein further comprises an inhibitor and/or a stabilizing agent.
• a support material described herein comprises a phase change wax component.
• a phase change wax component in some embodiments, is operable to assist or accelerate the solidification of the support material when the support material is cooled to or below the freezing point of the material.
• a phase change wax component has a sharp freezing point or a freezing point over a narrow range of temperatures.
• a phase change wax component freezes or solidifies over a temperature range of about 1° C. to about 5° C. or about 1° C. to about 3° C.
• phase change wax component not inconsistent with the objectives of the present disclosure may be used in a support material described herein.
• a phase change wax component of a support material described herein comprises a ketone wax, an ester wax, an alcohol wax, an amide wax, a urethane wax, or a mixture or combination thereof.
• a ketone wax in some cases, comprises an alkyl alkyl ketone, an alkyl aryl ketone, an aryl aryl ketone, an aryl arylalkyl ketone, an aryl alkylaryl ketone, an arylalkyl arylalkyl ketone, an arylalkyl alkylaryl ketone, or a combination or mixture of two or more of the foregoing.
• a ketone wax of a phase change wax component described herein comprises an alkyl alkyl ketone having the general formula R—(C ⁇ O)—R′, wherein R and R′ are each independently an alkyl group having between 1 and 36 carbon atoms, provided that at least one of R and R′ is an alkyl group having at least 4 carbon atoms. In some cases, such an alkyl group is linear.
• An alkyl group of a ketone wax described herein can also be branched, cyclic, saturated, unsaturated, substituted, or unsubstituted.
• alkyl alkyl ketones suitable for use in some embodiments of support materials described herein include n-octyl-n-propyl ketone; n-octyl-n-butyl ketone, n-decyl-n-ethyl ketone, n-undecyl-n-propyl ketone, n-dodecyl-n-ethyl ketone, di-n-hexylketone, di-n-heptylketone, di-n-octyl ketone, di-n-nonyl ketone, di-n-decyl ketone, di-n-undecyl ketone, di-n-tridecyl ketone, di-n-heptadecyl ketone, di-n-octadecyl ketone, and mixtures or combinations thereof.
• Other alkyl alkyl ketones may also be used
• a ketone wax of a phase change wax component described herein can also comprise an alkyl aryl ketone having the general formula R—(C ⁇ O)—Ar, wherein R is an alkyl group as described above for an alkyl alkyl ketone, and Ar is an aryl group having 6 to 36 carbon atoms.
• the aryl group in some cases, comprises a substituted or unsubstituted phenyl, naphthyl, or anthryl group.
• Non-limiting examples of alkyl aryl ketones suitable for use in some embodiments of support materials described herein include n-octyl phenyl ketone, n-undecyl phenyl ketone, n-pentadecyl phenyl ketone, n-octadecyl phenyl ketone, and mixtures or combinations thereof.
• Other alkyl aryl ketones may also be used.
• a ketone wax of a phase change wax component described herein comprises an aryl aryl ketone having the general formula Ar—(C ⁇ O)—Ar′, wherein Ar and Ar′ are each independently an aryl group described above for alkyl aryl ketones.
• aryl aryl ketones suitable for use in some embodiments of support materials described herein include diphenyl acetone, 2-naphthyl phenyl ketone, and mixtures or combinations thereof. Other aryl aryl ketones may also be used.
• a ketone wax of a phase change wax component described herein can also comprise an aryl arylalkyl ketone or an aryl alkylaryl ketone having the general formula Ar—(C ⁇ O)—Ar′R or Ar—(C ⁇ O)—RAr′, wherein R is an alkyl group described hereinabove for an alkyl alkyl ketone, and Ar and Ar′ are each independently an aryl group described hereinabove for an aryl aryl ketone.
• R is an alkyl group described hereinabove for an alkyl alkyl ketone
• Ar and Ar′ are each independently an aryl group described hereinabove for an aryl aryl ketone.
• An aryl alkylaryl ketone suitable for use in some embodiments of support materials described herein is benzyl phenyl ketone.
• Other aryl arylalkyl ketones or aryl alkylaryl ketones may also be used.
• a ketone wax of a phase change wax component described herein comprises an arylalkyl arylalkyl ketone, an arylalkyl alkylaryl ketone, or an alkylaryl alkylaryl ketone having the general formula RAr—(C ⁇ O)—Ar′R, RAr—(C ⁇ O)—R′Ar′, or ArR—(C ⁇ O)—R′Ar′, wherein Ar and Ar′ are each independently an aryl group described above and R and R′ are each independently an alkyl group described above.
• a ketone is di-n-benzyl ketone. Other such ketones may also be used.
• a ketone wax described herein comprises a substituted alkyl, aryl, alkylaryl, or arylalkyl group
• one or more substituents of the substituted group in some cases, can comprise a hydroxy group, amine group, imine group, ammonium group, pyridine group, pyridinium group, ether group, ester group, amide group, carbonyl group, thiocarbonyl group, sulfate group, sulfonate group, sulfide group, sulfoxide group, phosphine group, phosphonium group, phosphate group, mercapto group, nitroso group, sulfone group, acyl group, acid anhydride group, or azide group.
• ketone waxes suitable for use in some embodiments of support materials described herein include stearones such as T-1 (Kao Corporation); KLB-766 (C21-(C ⁇ O)—C21 ketone) (Kao Corporation); and KLB-770 (C17-(C ⁇ O)—C17 ketone) (Kao Corporation), and/or laurones such as LAURONE (Kanto Kagaku Co. Ltd.).
• An ester wax in some embodiments, comprises an alkyl alkyl ester, an alkyl aryl ester, an aryl aryl ester, an aryl arylalkyl ester, an aryl alkylaryl ester, an arylalkyl arylalkyl ester, an arylalkyl alkylaryl ester, an alkylaryl alkylaryl ester, or a combination or mixture of two or more of the foregoing.
• an ester wax of a phase change wax component described herein comprises an ester having the general formula R—(C ⁇ O)—OR′, wherein R and R′ are each independently an alkyl group described hereinabove for ketone waxes, such as an alkyl group having between 1 and 36 carbon atoms, provided that at least one of R and R′ is an alkyl group having at least 4 carbon atoms. In some cases, such an alkyl group is linear.
• An alkyl group of an ester wax described herein can also be branched, cyclic, saturated, unsaturated, substituted, or unsubstituted.
• An ester wax can also have the general formula R—(C ⁇ O)—OAr, RO—(C ⁇ O)—Ar, Ar—(C ⁇ O)—OAr′, ArO—(C ⁇ O)—RAr′, Ar—(C ⁇ O)—ORAr′, ArO—(C ⁇ O)—Ar′R, Ar—(C ⁇ O)—OAr′R, ArR—(C ⁇ O)—OAr′R, ArR—(C ⁇ O)—OR′Ar′, or RAr—(C ⁇ O)—OR′Ar′, wherein Ar and Ar′ are each independently an aryl group described above and R and R′ are each independently an alkyl group described above.
• Ar and Ar′ are each an aryl group having 6 to 36 carbon atoms.
• an ester wax suitable for use in some embodiments described herein is methyl behenate (CH 3 O—(C ⁇ O)—CH 2 (CH 2 ) 20 CH 3 ).
• Other ester waxes may also be used.
• an ester wax described herein comprises a substituted alkyl, aryl, alkylaryl, or arylalkyl group
• one or more substituents of the substituted group in some cases, can comprise a substituent group described hereinabove for substituted ketone waxes.
• An alcohol wax in some instances, comprises a fatty alcohol. Any fatty alcohol not inconsistent with the objectives of the present disclosure may be used. In some cases, a fatty alcohol has the general formula C n H 2n+1 OH, wherein n is an integer from 6 to 36 or from 8 to 28.
• a fatty alcohol comprises decanol (C 10 H 21 OH), dodecanol (C 12 H 25 OH), tetradecanol (C 14 H 29 OH), hexadecanol (C 16 H 33 OH), octadecanol (C 18 H 37 OH), eicosanol (C 20 H 41 OH) or docosanol (C 22 H 45 OH), or a mixture or combination thereof.
• a fatty alcohol described herein in some cases, can be a primary alcohol such as stearyl alcohol or behenyl alcohol. Other fatty alcohols may also be used.
• an alcohol wax described herein can also comprise a synthetic long chain alcohol or a hydroxyl-terminated hydrophobic polymer, such as a hydroxyl-terminated polyethylene.
• an alcohol wax described herein comprises UNILIN 350, UNILIN 425, UNILIN 550, and/or UNILIN 700.
• An amide wax in some embodiments, comprises an alkyl alkyl amide or bis(amide), an alkyl aryl amide or bis(amide), an aryl aryl amide or bis(amide), an aryl arylalkyl amide or bis(amide), an aryl alkylaryl amide or bis(amide), an arylalkyl arylalkyl amide or bis(amide), an arylalkyl alkylaryl amide or bis(amide), an alkylaryl alkylaryl amide or bis(amide), or a combination or mixture of two or more of the foregoing.
• an amide wax of a phase change wax component described herein comprises ethylene bis(stearamide) (EBS).
• an amide has the general formula R—(C ⁇ O)—NHR′, wherein R and R′ are each independently an alkyl group described hereinabove, such as an alkyl group having between 1 and 36 carbon atoms, provided that at least one of R and R′ is an alkyl group having at least 4 carbon atoms. In some cases, such an alkyl group is linear.
• An alkyl group of an amide wax described herein can also be branched, cyclic, saturated, unsaturated, substituted, or unsubstituted.
• An amide wax can also have the general formula R—(C ⁇ O)—NR′′Ar, RNR′′—(C ⁇ O)—Ar, Ar—(C ⁇ O)—NR′′Ar′, ArNR′′—(C ⁇ O)—RAr′, Ar—(C ⁇ O)—NR′′RAr′, ArNR′′—(C ⁇ O)—Ar′R, Ar—(C ⁇ O)—NR′′Ar′R, ArR—(C ⁇ O)—NR′′Ar′R, ArR—(C ⁇ O)—NR′′R′Ar′, or RAr—(C ⁇ O)—NR′′R′Ar′, wherein Ar and Ar′ are each independently an aryl group described above, R and R′ are each independently an alkyl group described above, and R′′ is hydrogen or an alkyl group described above.
• Ar and Ar′ are each an aryl group having 6 to 36 carbon atoms.
• One non-limiting example of an amide wax suitable for use in some embodiments described herein is stearyl stearamide (CH 3 (CH 2 ) 17 —(C ⁇ O)—NH(CH 2 ) 17 CH 3 ).
• Other amide waxes may also be used.
• a urethane wax in some embodiments, is selected from a class of inert linear urethane waxes having the general chemical formula C 18 H 37 NRCOOC x H (2x+1) wherein x is an integer from 4 to 16 or 4 to 22, and R is H or C1-C20 alkyl. In some cases, R is H. In some embodiments, R is C1-C6 alkyl, C1-C10 alkyl, or C1-C20 alkyl.
• a urethane wax is selected from a class of reactive linear urethane waxes having the formula C x H (2x+1) NRC(O)OC y H 2y OC(O)C(CH 3 ) ⁇ CH 2 wherein x is an integer from 12 to 18, y is an integer from 2 to 12, and R is H or C1-C20 alkyl. In some embodiments, R is H. In other cases, R is C1-C6 alkyl, C1-C10 alkyl, or C1-C20 alkyl.
• Non-limiting examples of urethane waxes suitable for use in some embodiments of support materials described herein include 1-dodecyl-N-octadecyl carbamate (CH 3 (CH 2 ) 17 NHCOO(CH 2 ) 11 CH 3 ) and 1-hexadecyl-N-octadecyl carbamate (CH 3 (CH 2 ) 17 NHCOO(CH 2 ) 15 CH 3 ).
• Other urethane waxes may also be used.
• the chemical composition of a phase change wax component of a support material described herein can be selected based on one or more desired properties of the phase change wax component and/or the support material comprising the phase change wax component.
• the chemical composition of a phase change wax component is selected such that the phase change wax component has a melting point centered from 40° C. to 110° C. or from 60° C. to 90° C. at a pressure of 1 atm.
• the chemical composition of a phase change wax component is selected such that the phase change wax component is miscible with an ethoxylated polyethylene of the support material, as described further hereinbelow.
• phase change wax component of a support material described herein can be present in the support material in any amount not inconsistent with the objectives of the present disclosure.
• the phase change wax component is present in an amount of 20-80% by weight, 30-70% by weight, 40-60% by weight, or 45-55% by weight, based on the total weight of the support material.
• Support materials described herein also comprise an ethoxylated polyethylene component, the ethoxylated polyethylene having the formula H—(CH 2 ) m —(OCH 2 CH 2 ) n —OH, wherein m is an integer from 22 to 60 and n is an integer from 2 to 200. In some cases, m is an integer from 30 to 40 and/or n is an integer from 10 to 100 or from 60 to 90. Selecting such values of m and n, in some embodiments, can permit miscibility or other chemical or physical compatibility of the ethoxylated polyethylene with one or more other components of the support material, such as one or more phase change wax components of the support material.
• the ethoxylated polyethylene of a support material described herein is miscible with at least two of, at least three of, or at least four of a ketone wax, an ester wax, an alcohol wax, and an amide wax at a temperature of 70-95° C. and a pressure of 1 atm.
• the ethoxylated polyethylene and the phase change wax component of a support material described herein are miscible at a temperature of 70-95° C. and a pressure of 1 atm. Materials that are “miscible” with one another can form a single phase when mixed, as opposed to forming a plurality of separate phases.
• Non-limiting examples of ethoxylated polyethylenes suitable for use in some embodiments of support materials described herein include UNITHOX 450, UNITHOX 480, UNITHOX 550, and UNITHOX 750.
• an ethoxylated polyethylene can be present in a support material described herein in any amount not inconsistent with the objectives of the present disclosure.
• the ethoxylated polyethylene is present in an amount of 20-80% by weight, 30-70% by weight, 40-60% by weight, or 45-55% by weight, based on the total weight of the support material.
• an ethoxylated polyethylene described herein can be at least partially replaced in a support material with one or more other species, such as one or more water dispersible or water soluble polymers other than an ethoxylated polyethylene.
• an ethoxylated polyethylene is at least partially replaced by a polyethylene glycol (PEG).
• PEG polyethylene glycol
• a “water dispersible” polymer in some cases, can comprise any hydrophilic or amphiphilic polymer that can be dispersed in water, including water at a temperature at or near room temperature (25° C.), such as a temperature of 20-30° C.
• a support material described herein further comprises a tackifier.
• a tackifier in some cases, can increase the adhesiveness of the support material to a printing substrate and/or a build material, as described further hereinbelow. Any tackifier not inconsistent with the objectives of the present disclosure may be used.
• a tackifier comprises a rosin ester, a rosin alcohol, or a mixture or combination thereof. Any rosin ester or rosin alcohol not inconsistent with the objectives of the present disclosure may be used.
• a rosin ester comprises the reaction product of an alcohol with a rosin acid.
• the alcohol in some embodiments, comprises methanol, glycerol, diethylene glycol, triethylene glycol, and/or pentaerythritol.
• the rosin acid in some cases, comprises one or more of abietic acid, neoabietic acid, dehydroabietic acid, palustric acid, pimaric acid, isopimaric acid, levopimaric acid, and sandaracopimaric acid.
• a rosin ester is at least partially hydrogenated.
• a rosin alcohol in some embodiments, comprises the reaction product of the hydrogenation of one or more rosin acids, including rosin acids described hereinabove. Further, in some cases, a rosin alcohol comprises a primary alcohol, such as hydroabietyl alcohol.
• a tackifier can be present in a support material described herein in any amount not inconsistent with the objectives of the present disclosure. In some cases, for instance, a tackifier is present in an amount of 2-30% by weight, 5-25% by weight, or 10-20% by weight, based on the total weight of the support material.
• a support material described herein further comprises an inhibitor or stabilizing agent.
• An inhibitor or stabilizing agent in some cases, can prevent or inhibit the polymerization, oxidation, or other reaction or degradation of one or more components of a support material described herein. Any inhibitor or stabilizing agent not inconsistent with the objectives of the present disclosure may be used.
• an inhibitor or stabilizing agent comprises one or more anti-oxidants.
• an inhibitor or stabilizing agent comprises an aryl compound such as butylated hydroxytoluene (BHT). Other inhibitors or stabilizing agents may also be used.
• an inhibitor or stabilizing agent can be present in a support material described herein in any amount not inconsistent with the objectives of the present disclosure.
• an inhibitor or stabilizing agent is present in a support material in an amount up to about 10% by weight or up to about 5% by weight, based on the total weight of the support material.
• an inhibitor or stabilizing agent is present in a support material in an amount ranging from about 0.1% by weight to about 10% by weight, from about 0.1% by weight to about 5% by weight, or from about 0.5% by weight to about 4% by weight, based on the total weight of the support material.
• Support materials having a composition described herein can be water dispersible or water soluble.
• a “water dispersible” support material in some cases, can be completely or substantially completely dispersed in water within 18 hours or less, within 8 hours or less, within 2 hours or less, within 1 hour or less, within 30 minutes or less, within 15 minutes or less, within 5 minutes or less, within 3 minutes or less, within 2 minutes or less, or within 1 minute or less when immersed in water, with or without agitation of the water.
• a support material that is “substantially dispersed” in water in some embodiments, is present in the water as solvated chemical species and/or as colloidal or suspended particles in an amount of at least about 80% by weight, at least about 90% by weight, at least about 95% by weight, or at least about 99% by weight, based on the total weight of the support material.
• the water is at a temperature of 20-30° C., such as a temperature of 25° C.
• a support material described herein is self-emulsifying when contacted with water or a continuous aqueous phase.
• an aqueous dispersion of a support material described herein can be directly disposed of in a wastewater treatment system without further chemical and/or physical processing prior to entry into the wastewater treatment system.
• an aqueous dispersion of a support material described herein can be disposed of in a municipal wastewater treatment system without further chemical and/or physical processing or treatment prior to entry into the municipal wastewater treatment system.
• a support material described herein is biodegradable.
• support materials described herein can have a melting point or freezing point consistent with the temperature parameters of one or more 3D printing systems.
• a support material has a melting point ranging from about 45° C. to about 95° C., from about 45° C. to about 70° C., from about 50° C. to about 65° C., from about 55° C. to about 63° C., or from about 60° C. to about 62° C.
• a support material described herein has a freezing point ranging from about 45° C. to about 55° C., from about 47° C. to about 52° C., or from about 49° C. to about 51° C.
• a support material described herein has a viscosity consistent with the requirements and parameters of one or more 3D printing systems.
• a support material described herein has a viscosity ranging from about 9.0 centipoise (cP) to about 14.0 cP at a temperature of about 65° C., when measured according to ASTM standard D2983 (e.g., using a Brookfield Model DV-II+ Viscometer).
• a support material has a viscosity ranging from about 9.5 cP to about 12.0 cP or from about 10.0 cP to 11.0 cP at a temperature of about 65° C.
• a support material described herein has a viscosity ranging from about 10.0 cP to about 19.0 cP, from about 11.0 cP to about 14.0 cP, from about 11.5 cP to about 13.5 cP, or from about 12.0 cP to about 13.0 cP at a temperature of about 80° C.
• a support material described herein is non-curable or does not polymerize or substantially polymerize when irradiated with electromagnetic radiation used in free radical polymerizations.
• a support material described herein does not comprise a chemical species having one or more ethyleneically unsaturated moieties, such as one or more acrylate, methacrylate, or vinyl species.
• such a chemical species is present in a support material described herein in an amount of no greater than about 5% by weight, no greater than about 1% by weight, no greater than about 0.5% by weight, or no greater than about 0.1% by weight, based on the total weight of the support material.
• a support material described herein can be combined or mixed in any ratio not inconsistent with the objectives of the present disclosure.
• General guidelines for establishing a suitable ratio of components can include maintaining the water dispersibility of the support material while providing sufficient mechanical integrity to the support material for use in 3D printing systems, or providing a desired viscosity of the support material for one or more specific jetting temperatures or deposition rates of a 3D printing system.
• a method for the preparation of a support material described herein comprises the steps of mixing the components of the support material, melting the mixture, and filtering the molten mixture. Melting the mixture, in some embodiments, is carried out at a temperature of about 55° C. or in a range from about 40° C. to about 110° C.
• a support material described herein is produced by placing all components of the support material in a reaction vessel and heating the resulting mixture to a temperature ranging from about 40° C. to about 110° C. with stirring. The heating and stirring are continued until the mixture attains a substantially homogenized molten state. In general, the molten mixture can be filtered while in a flowable state to remove any large undesirable particles that may interfere with jetting.
• compositions are described herein.
• a composition comprises a three-dimensionally printed article comprising a build material and a support material, wherein the support material comprises a support material described hereinabove in Section I.
• the support material comprises a wax component and an ethoxylated polyethylene having the formula H—(CH 2 ) m —(OCH 2 CH 2 ) n —OH, wherein m is an integer from 22 to 60 or from 30 to 40, and n is an integer from 2 to 200 or from 10 to 100.
• the phase change wax component and the ethyoxylated polyethylene are each present in the support material in an amount of 20-80% by weight or 40-60% by weight, based on the total weight of the support material.
• the support material of a composition described herein further comprises a tackifier such as a rosin ester, a rosin alcohol, or a mixture or combination thereof.
• the support material of a composition described herein in some cases, can be water dispersible, including when immersed or contacted with water at a temperature of 20-30° C.
• compositions described herein also comprise a build material.
• the support material of a three-dimensionally printed article supports one or more layers of build material used in the fabrication of the article. Any build material not inconsistent with the objectives of the present disclosure may be used.
• the build material comprises a curable material.
• the curable material can be present in the build material in any amount not inconsistent with the objectives of the present disclosure.
• the curable material is present in an amount up to about 99% by weight, up to about 95% by weight, up to about 90% by weight, or up to about 80% by weight, based on the total weight of the build material.
• a build material described herein comprises about 10-95 weight % curable material, based on the total weight of the build material.
• a build material comprises about 20-80 weight % curable material, about 30-70 weight % curable material, or about 70-90 weight % curable material.
• a curable material comprises one or more polymerizable components.
• a “polymerizable component,” for reference purposes herein, comprises a component that can be polymerized or cured to provide a printed 3D article or object.
• Polymerizing or curing can be carried out in any manner not inconsistent with the objectives of the present disclosure.
• polymerizing or curing comprises irradiating with electromagnetic radiation having sufficient energy to initiate a polymerization or cross-linking reaction. For instance, in some embodiments, ultraviolet (UV) radiation can be used.
• electromagnetic radiation having sufficient energy to initiate a polymerization or cross-linking reaction.
• ultraviolet (UV) radiation can be used.
• a polymerizable component comprises a monomeric chemical species, such as a chemical species having one or more functional groups or moieties that can react with the same or different functional groups or moieties of another monomeric chemical species to form one or more covalent bonds, such as in a polymerization reaction.
• a polymerization reaction in some embodiments, comprises a free radical polymerization, such as that between points of unsaturation, including points of ethylenic unsaturation.
• a polymerizable component comprises at least one ethyleneically unsaturated moiety, such as a vinyl group or allyl group.
• a polymerizable component comprises an oligomeric chemical species capable of undergoing additional polymerization, such as through one or more points of unsaturation as described herein.
• a polymerizable component comprises one or more monomeric chemical species and one or more oligomeric chemical species described herein.
• a monomeric chemical species and/or an oligomeric chemical species described herein can have one polymerizable moiety or a plurality of polymerizable moieties.
• a polymerizable component comprises one or more photo-polymerizable or photo-curable chemical species.
• a photo-polymerizable chemical species in some embodiments, comprises a UV-polymerizable chemical species.
• a polymerizable component is photo-polymerizable or photo-curable at wavelengths ranging from about 300 nm to about 400 nm.
• a polymerizable component is photo-polymerizable at visible wavelengths of the electromagnetic spectrum.
• a polymerizable component described herein comprises one or more species of (meth)acrylates.
• (meth)acrylate includes acrylate or methacrylate or mixtures or combinations thereof.
• a polymerizable component comprises an aliphatic polyester urethane acrylate oligomer, a urethane(meth)acrylate resin, and/or an acrylate amine oligomeric resin.
• a UV polymerizable or curable resin or oligomer can comprise any methacrylate or acrylate resin which polymerizes in the presence of a free radical photoinitiator, is thermally stable in an exposed state for at least one week at the jetting temperature and for at least 4 weeks in an enclosed state, and/or has a boiling point greater than the jetting temperature.
• a polymerizable component has a flash point above the jetting temperature.
• Urethane(meth)acrylates suitable for use in build materials described herein can be prepared in a known manner, typically by reacting a hydroxyl-terminated urethane with acrylic acid or methacrylic acid to give the corresponding urethane(meth)acrylate, or by reacting an isocyanate-terminated prepolymer with hydroxyalkyl acrylates or methacrylates to give the urethane(meth)acrylate.
• Suitable processes are disclosed, inter alia, in EP-A 114 982 and EP-A 133 908.
• the weight average molecular weight of such (meth)acrylate oligomers is generally in the range from about 400 to 10,000, or from about 500 to 7,000.
• Urethane(meth)acrylates are also commercially available from the SARTOMER Company under the product names CN980, CN981, CN975 and CN2901, or from Bomar Specialties Co. (Winsted, Conn.) under the product name BR-741.
• a urethane(meth)acrylate oligomer has a viscosity ranging from about 140,000 cP to about 160,000 cP at about 50° C. or from about 125,000 cP to about 175,000 cP at about 50° C. when measured in a manner consistent with ASTM D2983.
• a urethane(meth)acrylate oligomer has a viscosity ranging from about 100,000 cP to about 200,000 cP at about 50° C. or from about 10,000 cP to about 300,000 cP at about 50° C. when measured in a manner consistent with ASTM D2983.
• a polymerizable component comprises one or more low molecular weight materials, such as methacrylates, dimethacrylates, triacrylates, and diacrylates, which can be used in a variety of combinations.
• a polymerizable component comprises one or more of tetrahydrofurfuryl methacrylate, triethylene glycol dimethacrylate, 2-phenoxyethyl methacrylate, lauryl methacrylate, ethoxylated trimethylolpropane triacrylate, tricyclodecane dimethanol diacrylate, 2-phenoxyethylacrylate, triethylene glycol diacrylate, a monofunctional aliphatic urethane acrylate, polypropylene glycol monomethacrylate, polyethylene glycol monomethacrylate, cyclohexane dimethanol diacrylate, and tridecyl methacrylate.
• a polymerizable component comprises diacrylate and/or dimethacrylate esters of aliphatic, cycloaliphatic or aromatic diols, including 1,3- or 1,4-butanediol, neopentyl glycol, 1,6-hexanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, tripropylene glycol, ethoxylated or propoxylated neopentyl glycol, 1,4-dihydroxymethylcyclohexane, 2,2-bis(4-hydroxycyclohexyl)propane or bis(4-hydroxycyclohexyl)methane, hydroquinone, 4,4′-dihydroxybiphenyl, bisphenol A, bisphenol F, bisphenol S, ethoxylated or propoxylated bisphenol A, ethoxylated or propoxylated bisphenol F or ethoxylated or propoxylated bisphenol F or e
• a polymerizable component in some embodiments, comprises one or more tri(meth)acrylates, such as 1,1-trimethylolpropane triacrylate or methacrylate, ethoxylated or propoxylated 1,1,1-trimethylolpropanetriacrylate or methacrylate, ethoxylated or propoxylated glycerol triacrylate, pentaerythritol monohydroxy triacrylate or methacrylate, and/or tris(2-hydroxy ethyl) isocyanurate triacrylate.
• tri(meth)acrylates such as 1,1-trimethylolpropane triacrylate or methacrylate, ethoxylated or propoxylated 1,1,1-trimethylolpropanetriacrylate or methacrylate, ethoxylated or propoxylated glycerol triacrylate, pentaerythritol monohydroxy triacrylate or methacrylate, and/or tris(2-hydroxy ethyl)
• a polymerizable component of a build material described herein can also comprise one or more higher functional acrylates or methacrylates such as dipentaerythritol monohydroxy pentaacrylate or bis(trimethylolpropane)tetraacrylate.
• a (meth)acrylate of a build material has a molecular weight ranging from about 250 to 700.
• a polymerizable component comprises allyl acrylate, allyl methacrylate, methyl(meth)acrylate, ethyl(meth)acrylate, n-propyl(meth)acrylate, n-butyl(meth)acrylate, isobutyl(meth)acrylate, n-hexyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, n-octyl(meth)acrylate, n-decyl(meth)acrylate and n-dodecyl(meth)acrylate, 2-hydroxyethyl(meth)acrylate, 2- and 3-hydroxypropyl(meth)acrylate, 2-methoxyethyl(meth)acrylate, 2-ethoxyethyl(meth)acrylate and 2- or 3-ethoxypropyl(meth)acrylate, tetrahydrofurfuryl methacrylate, 2-(2-ethoxy
• species of polymerizable components useful in some embodiments described herein include the following: isobornyl acrylate (IBOA), commercially available from SARTOMER under the trade name SR 506A; isobornyl methacrylate, commercially available from SARTOMER under the trade name SR 423A; and triethylene glycol dimethacrylate, commercially available from SARTOMER under the trade name SR 205.
• IBOA isobornyl acrylate
• SR 506A isobornyl methacrylate
• SR 423A commercially available from SARTOMER under the trade name SR 423A
• triethylene glycol dimethacrylate commercially available from SARTOMER under the trade name SR 205.
• Build materials described herein can further comprise one or more additives, such as one or more additives selected from the group consisting of photoinitiators, inhibitors, stabilizing agents, sensitizers, and combinations thereof.
• a build material further comprises one or more photoinitiators. Any photoinitiator not inconsistent with the objectives of the present disclosure can be used.
• a photoinitiator comprises an alpha-cleavage type (unimolecular decomposition process) photoinitiator or a hydrogen abstraction photosensitizer-tertiary amine synergist, operable to absorb light preferably between about 250 nm and about 400 nm or between about 300 nm and about 385 nm, to yield free radical(s).
• alpha cleavage photoinitiators examples include Irgacure 184 (CAS 947-19-3), Irgacure 369 (CAS 119313-12-1), and Irgacure 819 (CAS 162881-26-7).
• An example of a photosensitizer-amine combination is Darocur BP (CAS 119-61-9) with diethylaminoethylmethacrylate.
• suitable photoinitiators comprise benzoins, including benzoin, benzoin ethers, such as benzoin methyl ether, benzoin ethyl ether and benzoin isopropyl ether, benzoin phenyl ether and benzoin acetate, acetophenones, including acetophenone, 2,2-dimethoxyacetophenone and 1,1-dichloroacetophenone, benzil, benzil ketals, such as benzil dimethyl ketal and benzil diethyl ketal, anthraquinones, including 2-methylanthraquinone, 2-ethylanthraquinone, 2-tert-butylanthraquinone, 1-chloroanthraquinone and 2-amylanthraquinone, triphenylphosphine, benzoylphosphine oxides, for example 2,4,6-trimethylbenzoyldiphenylphosphine
• suitable photoinitiators comprise those operable for use with an Ar laser radiation source including benzil ketals, such as benzil dimethyl ketal.
• a photoinitiator comprises an ⁇ -hydroxyphenyl ketone, benzil dimethyl ketal or 2,4,6-trimethylbenzoyldiphenylphosphine oxide or a mixture thereof.
• ionic dye-counter ion compounds capable of absorbing actinic radiation and generating free radicals for polymerization initiation.
• build materials containing ionic dye-counter ion compounds can be cured more variably with visible light within the adjustable wavelength range of about 400 nm to about 700 nm.
• Ionic dye-counter ion compounds and their mode of operation are disclosed in EP-A-0 223 587 and U.S. Pat. Nos. 4,751,102; 4,772,530; and 4,772,541.
• a photoinitiator can be present in a build material described herein in any amount not inconsistent with the objectives of the present disclosure.
• a photoinitiator is present in a build material in an amount of up to about 5 weight percent, based on the total weight of the build material. In some embodiments, a photoinitiator is present in an amount ranging from about 0.1 weight percent to about 5 weight percent.
• a build material further comprises one or more sensitizers.
• a sensitizer can be added to a build material to increase the effectiveness of one or more photoinitiators that may also be present. Any sensitizer not inconsistent with the objectives of the present disclosure may be used.
• a sensitizer comprises isopropylthioxanthone (ITX). In other cases, a sensitizer comprises 2-chlorothioxanthone (CTX).
• a sensitizer can be present in a build material in any amount not inconsistent with the objectives of the present disclosure.
• a sensitizer is present in an amount ranging from about 0.1 weight percent to about 2 weight percent or from about 0.5 weight percent to about 1 weight percent, based on the total weight of the build material.
• a build material of a composition described herein further comprises one or more polymerization inhibitors or stabilizing agents.
• a polymerization inhibitor can be added to a build material to provide additional thermal stability to the composition. Any polymerization inhibitor not inconsistent with the objectives of the present disclosure may be used.
• a polymerization inhibitor comprises methoxyhydroquinone (MEHQ).
• a stabilizing agent can comprise one or more anti-oxidants such as an aryl compound such as BHT.
• a polymerization inhibitor and/or a stabilizing agent can be present in a build material in any amount not inconsistent with the objectives of the present disclosure.
• a polymerization inhibitor or a stabilizing agent is present in an amount ranging from about 0.1 weight percent to about 5 weight percent, from about 0.1 weight percent to about 2 weight percent, from about 0.5 weight percent to 1 weight percent, or from about 0.5 weight percent to about 4 weight percent, based on the total weight of the build material.
• a build material described herein can also exhibit a variety of other desirable properties.
• a build material described herein can have any freezing point, melting point, and/or other phase transition temperature not inconsistent with the objectives of the present disclosure.
• a build material has a freezing or melting point consistent with temperatures used in some 3D printing systems, including 3D printing systems designed for use with phase changing build materials.
• the freezing point of a build material is greater than about 40° C.
• a build material has a freezing point centered at a temperature ranging from about 45° C. to about 55° C. or from about 50° C. to about 80° C.
• a build material has a freezing point below about 40° C. or below about 30° C.
• a build material exhibits a sharp freezing point or other phase transition.
• a build material freezes over a narrow range of temperatures, such as a temperature range of about 1° C. to about 10° C., about 1° C. to about 8° C., or about 1° C. to about 5° C.
• a build material described herein in some embodiments, is fluid at jetting temperatures encountered in 3D printing systems.
• a build material solidifies once deposited on a surface during the fabrication of a three-dimensionally printed article or object.
• a build material remains substantially fluid upon deposition on a surface.
• Solidification of a build material occurs through a phase change of the build material, such as freezing.
• the phase change in some embodiments, comprises a liquid to solid phase change or a liquid to semi-solid phase change.
• solidification of a build material comprises an increase in viscosity, such as an increase in viscosity from a low viscosity state to a high viscosity state, as described further hereinbelow.
• a build material described herein can have a viscosity profile consistent with the requirements and parameters of one or more 3D printing systems.
• a build material described herein has a viscosity ranging from about 8.0 cP to about 19.0 cP, from about 8.0 to about 13.5 cP, or from about 11.0 cP to about 14.0 cP at a temperature of about 65° C. when measured according to ASTM standard D2983.
• a build material described herein has a viscosity ranging from about 8.0 cP to about 14.0 cP, from about 9.5 cP to about 12.5 cP, or from about 10.5 cP to about 12.5 cP at a temperature of about 80° C. In some cases, a build material has a viscosity ranging from about 8.0 cP to about 10.0 cP at a temperature of about 85-87° C.
• build materials described herein exhibit a combination of one or more desirable features.
• a build material in the non-cured state has one or more of the following properties:
• Viscosity can be measured according to ASTM D2983 (e.g., using a Brookfield Model DV-II+ Viscometer).
• a thermally stable material exhibits no greater than about a 35 percent change in viscosity over a specified time period (e.g., 3 days) when measured at the specified temperature (e.g., a jetting temperature of 85° C.) at the beginning and at the end of the time period.
• the viscosity change is no greater than about 30 percent or no greater than about 20 percent, or between about 10 percent and about 20 percent or between about 25 percent and about 30 percent.
• the change in viscosity is an increase in viscosity.
• a build material described herein in a cured state can exhibit one or more desired properties.
• a build material in a cured state comprises a build material that includes a curable material or polymerizable component that has been at least partially polymerized and/or cross-linked.
• a cured build material is at least about 10% polymerized or cross-linked or at least about 30% polymerized or cross-linked.
• a cured build material is at least about 50%, at least about 70%, at least about 80%, or at least about 90% polymerized or cross-linked.
• a cured build material is between about 10% and about 99% polymerized or cross-linked.
• a build material described herein can have one or more of the following properties:
• a method for the preparation of a build material described herein comprises the steps of mixing the components of the build material, melting the mixture, and filtering the molten mixture. Melting the mixture, in some embodiments, is carried out at a temperature of about 75° C. or in a range from about 75° C. to about 85° C.
• a build material described herein is produced by placing all components of the build material in a reaction vessel and heating the resulting mixture to a temperature ranging from about 75° C. to about 85° C. with stirring. The heating and stirring are continued until the mixture attains a substantially homogenized molten state.
• the molten mixture can be filtered while in a flowable state to remove any large undesirable particles that may interfere with jetting. The filtered mixture is then cooled to ambient temperatures until it is heated in the 3D printer.
• a three-dimensionally printed article described herein comprises a plurality of layers of the build material, wherein the layers of the build material are deposited according to data in a computer readable format. Moreover, at least one of the deposited layers of build material is supported by a support material described herein. The support material is removable to complete production of the three-dimensionally printed article or object of the composition.
• a method of printing a 3D article comprises selectively depositing layers of a fluid build material to form the 3D article on a substrate, and supporting at least one layer of the build material with a support material, the support material comprising a support material described hereinabove in Section I. Any support material described in Section I may be used in a method described herein.
• the support material comprises a wax component and an ethoxylated polyethylene having the formula H—(CH 2 ) m —(OCH 2 CH 2 ) n —OH, wherein m is an integer from 22 to 60 or from 30 to 40, and n is an integer from 2 to 200 or from 10 to 100.
• the phase change wax component and the ethyoxylated polyethylene are each present in the support material in an amount of 20-80% by weight or 40-60% by weight, based on the total weight of the support material.
• the support material of a method described herein further comprises a tackifier such as a rosin ester, a rosin alcohol, or a mixture or combination thereof.
• a tackifier such as a rosin ester, a rosin alcohol, or a mixture or combination thereof.
• the support material of a method described herein in some cases, can be water dispersible, including when immersed or contacted with water at a temperature of 20-30° C.
• the build material can comprise any embodiment of a build material described hereinabove in Section II.
• a method of printing a 3D article described herein further comprises curing the build material.
• a method further comprises subjecting the build material to electromagnetic radiation of sufficient wavelength and intensity to cure the build material.
• a layer of deposited build material in some instances, is cured prior to the deposition of another or adjacent layer of build material.
• a preselected amount of build material described herein is heated to the appropriate temperature and jetted through the print head or a plurality of print heads of a suitable 3D printer, such as a inkjet 3D printer, to form a layer onto a build support platform in a build chamber.
• a suitable 3D printer such as a inkjet 3D printer
• Each layer of build material can be deposited according to the preselected computer assisted design (CAD) parameters.
• CAD computer assisted design
• a suitable print head to deposit the build material in one embodiment, is the piezoelectric Z850 print head.
• Additional suitable print heads for the deposition of build and support materials described herein are commercially available from a variety of ink jet printing apparatus manufacturers. For example, a Xerox print head or Ricoh print heads may also be used.
• the temperature of the build environment can be controlled so that the jetted droplets of build material solidify on contact with the receiving surface. In other cases, the jetted droplets of build material do not solidify on contact with the receiving surface, remaining in a substantially fluid state.
• the deposited material is planarized and cured with electromagnetic (e.g., UV) radiation prior to the deposition of the next layer.
• electromagnetic radiation e.g., UV
• several layers can be deposited before planarization and curing, or multiple layers can be deposited and cured followed by one or more layers being deposited and then planarized without curing.
• Planarization can correct the thickness of one or more layers prior to curing the material by evening the dispensed material to remove excess material and create a uniformly smooth exposed or flat up-facing surface on the support platform of the printer.
• planarization is accomplished with a wiper device, such as a roller, which may be counter-rotating in one or more printing directions but not counter-rotating in one or more other printing directions.
• the wiper device comprises a roller and a wiper that removes excess material from the roller.
• the wiper device is heated.
• the consistency of the jetted build material prior to curing can be sufficient to retain its shape and not be subject to excessive viscous drag from the planarizer. The foregoing process can be continued until a finished 3D article is prepared.
• the support material in some embodiments, can be deposited in a manner consistent with that described herein for the build material.
• the support material for example, can be deposited according to the preselected CAD parameters such that the support material is adjacent or continuous with one or more layers of the build material. Jetted droplets of the support material, in some embodiments, solidify or freeze on contact with the receiving surface, as described hereinabove. Additionally, in some cases, the deposited support material is also subjected to planarization. Layered deposition of the build material and support material can be repeated until the 3D article has been formed.
• a method of printing a 3D article described herein further comprises removing the support material from the build material.
• support materials described herein are water dispersible and/or at least partially water soluble
• removing the support material from the build material comprises dispersing the support material in water.
• Dispersing the support material in water in some cases, comprises contacting the support material with flowing water.
• dispersing the support material in water comprises at least partially immersing the 3D article in a water bath.
• the water bath is stirred, or sonicated, or otherwise agitated during immersion of the 3D printed article.
• water used for the removal of a support material can be at any desired temperature not inconsistent with the objectives of the present disclosure.
• water for the removal of the support material can be heated to any temperature that does not deform or substantially deform or compromise the structure of the build material of the 3D printed article.
• water for removal of the support material is heated to a temperature ranging from about 40° C. to about 70° C.
• the water for the removal of the support material is at a temperature at or near room temperature, such as a temperature ranging from about 20° C. to about 35° C. or about 20° C. to about 30° C.
• one or more surfactants or detergents can be added to water used to remove the support material from the build material.
• no surfactants or detergents are intentionally added to the water.
• a method of printing a 3D article described herein further comprises disposing of the support material dispersed and/or at least partially solubilized in water without further treatment.
• an aqueous dispersion of a support material described herein can be disposed of in a wastewater treatment system without further chemical and/or physical processing prior to entry into the wastewater treatment system.
• an aqueous dispersion of a support material described herein can be disposed of in a municipal wastewater treatment system without further chemical and/or physical processing or treatment prior to entry into the municipal wastewater treatment system.
• Support materials according to some embodiments described herein were prepared as follows. Specifically, Support Materials 1 through 10 in Table I below were prepared by charging the components of each support material into a beaker, following by melting and stirring of the components at 110° C. All amounts in Table I are weights of the identified components in grams (g). Table II provides some properties of Support Materials 1-10. “DSC” in Table II refers to Differential Scanning calorimetry.
• test samples were made by casting support material compositions in a silicone mold with a finished 3D printed part formed from a build material. Following casting, the test samples were immersed in water at about 25° C. in glass jars for several hours without agitation. The test samples were then removed from the water and inspected to determine how much of the support material was removed from the printed part and dispersed in water.
• Support Materials 1-10 demonstrated a water dispersibility described hereinabove when evaluated in this manner.
• Support Materials 1-10 The water dispersibility of some of Support Materials 1-10 was also evaluated with agitation. Specifically, test samples similar to those described above were prepared and then heated in an oven at 93° C. to melt and drain off the majority of the support materials adhered to the printed part. The resulting samples were then immersed in 100 mL water at 25° C. and shaken and evaluated every 30 minutes until all of the support material was removed from printed part. The time needed to remove the support material was recorded. Support Materials 2, 5, 6, and 8 exhibited removal times of 2-4 hours when evaluated in this manner.
• Support Materials 1-10 were further evaluated with sonication (with ultrasound). Specifically, test samples were prepared by dipping finished 3D printed parts into the molten support materials. The resulting samples were permitted to cool and then were sonicated in a water bath to remove the support materials. The time needed to remove the support material was recorded. Support Materials 2, 3, 5, 6, 8, and 9 exhibited removal times of 1-2 hours when evaluated in this manner.

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