WO2020056316A1 - Chemical compositions for removing resin from a 3d-printed object and methods of making and using same - Google Patents
Chemical compositions for removing resin from a 3d-printed object and methods of making and using same Download PDFInfo
- Publication number
- WO2020056316A1 WO2020056316A1 PCT/US2019/051094 US2019051094W WO2020056316A1 WO 2020056316 A1 WO2020056316 A1 WO 2020056316A1 US 2019051094 W US2019051094 W US 2019051094W WO 2020056316 A1 WO2020056316 A1 WO 2020056316A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- ether
- glycol
- finishing solution
- weight
- finishing
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 47
- 229920005989 resin Polymers 0.000 title claims abstract description 28
- 239000011347 resin Substances 0.000 title claims abstract description 28
- 239000000126 substance Substances 0.000 title description 6
- 239000000203 mixture Substances 0.000 title description 2
- 239000000463 material Substances 0.000 claims abstract description 33
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims abstract description 21
- 150000003505 terpenes Chemical class 0.000 claims abstract description 13
- 235000007586 terpenes Nutrition 0.000 claims abstract description 13
- XMGQYMWWDOXHJM-JTQLQIEISA-N (+)-α-limonene Chemical compound CC(=C)[C@@H]1CCC(C)=CC1 XMGQYMWWDOXHJM-JTQLQIEISA-N 0.000 claims description 15
- -1 pinene Chemical compound 0.000 claims description 10
- 238000003756 stirring Methods 0.000 claims description 9
- POAOYUHQDCAZBD-UHFFFAOYSA-N 2-butoxyethanol Chemical compound CCCCOCCO POAOYUHQDCAZBD-UHFFFAOYSA-N 0.000 claims description 8
- QCAHUFWKIQLBNB-UHFFFAOYSA-N 3-(3-methoxypropoxy)propan-1-ol Chemical group COCCCOCCCO QCAHUFWKIQLBNB-UHFFFAOYSA-N 0.000 claims description 7
- 238000005507 spraying Methods 0.000 claims description 7
- ARXJGSRGQADJSQ-UHFFFAOYSA-N 1-methoxypropan-2-ol Chemical compound COCC(C)O ARXJGSRGQADJSQ-UHFFFAOYSA-N 0.000 claims description 6
- XMGQYMWWDOXHJM-UHFFFAOYSA-N limonene Chemical compound CC(=C)C1CCC(C)=CC1 XMGQYMWWDOXHJM-UHFFFAOYSA-N 0.000 claims description 5
- 238000000527 sonication Methods 0.000 claims description 4
- MGSRCZKZVOBKFT-UHFFFAOYSA-N thymol Chemical compound CC(C)C1=CC=C(C)C=C1O MGSRCZKZVOBKFT-UHFFFAOYSA-N 0.000 claims description 4
- LAVARTIQQDZFNT-UHFFFAOYSA-N 1-(1-methoxypropan-2-yloxy)propan-2-yl acetate Chemical compound COCC(C)OCC(C)OC(C)=O LAVARTIQQDZFNT-UHFFFAOYSA-N 0.000 claims description 3
- RWNUSVWFHDHRCJ-UHFFFAOYSA-N 1-butoxypropan-2-ol Chemical compound CCCCOCC(C)O RWNUSVWFHDHRCJ-UHFFFAOYSA-N 0.000 claims description 3
- IBLKWZIFZMJLFL-UHFFFAOYSA-N 1-phenoxypropan-2-ol Chemical compound CC(O)COC1=CC=CC=C1 IBLKWZIFZMJLFL-UHFFFAOYSA-N 0.000 claims description 3
- VXQBJTKSVGFQOL-UHFFFAOYSA-N 2-(2-butoxyethoxy)ethyl acetate Chemical compound CCCCOCCOCCOC(C)=O VXQBJTKSVGFQOL-UHFFFAOYSA-N 0.000 claims description 3
- WMDZKDKPYCNCDZ-UHFFFAOYSA-N 2-(2-butoxypropoxy)propan-1-ol Chemical compound CCCCOC(C)COC(C)CO WMDZKDKPYCNCDZ-UHFFFAOYSA-N 0.000 claims description 3
- GZMAAYIALGURDQ-UHFFFAOYSA-N 2-(2-hexoxyethoxy)ethanol Chemical compound CCCCCCOCCOCCO GZMAAYIALGURDQ-UHFFFAOYSA-N 0.000 claims description 3
- SBASXUCJHJRPEV-UHFFFAOYSA-N 2-(2-methoxyethoxy)ethanol Chemical compound COCCOCCO SBASXUCJHJRPEV-UHFFFAOYSA-N 0.000 claims description 3
- CUDYYMUUJHLCGZ-UHFFFAOYSA-N 2-(2-methoxypropoxy)propan-1-ol Chemical compound COC(C)COC(C)CO CUDYYMUUJHLCGZ-UHFFFAOYSA-N 0.000 claims description 3
- COBPKKZHLDDMTB-UHFFFAOYSA-N 2-[2-(2-butoxyethoxy)ethoxy]ethanol Chemical compound CCCCOCCOCCOCCO COBPKKZHLDDMTB-UHFFFAOYSA-N 0.000 claims description 3
- JDSQBDGCMUXRBM-UHFFFAOYSA-N 2-[2-(2-butoxypropoxy)propoxy]propan-1-ol Chemical compound CCCCOC(C)COC(C)COC(C)CO JDSQBDGCMUXRBM-UHFFFAOYSA-N 0.000 claims description 3
- WFSMVVDJSNMRAR-UHFFFAOYSA-N 2-[2-(2-ethoxyethoxy)ethoxy]ethanol Chemical compound CCOCCOCCOCCO WFSMVVDJSNMRAR-UHFFFAOYSA-N 0.000 claims description 3
- WAEVWDZKMBQDEJ-UHFFFAOYSA-N 2-[2-(2-methoxypropoxy)propoxy]propan-1-ol Chemical compound COC(C)COC(C)COC(C)CO WAEVWDZKMBQDEJ-UHFFFAOYSA-N 0.000 claims description 3
- NQBXSWAWVZHKBZ-UHFFFAOYSA-N 2-butoxyethyl acetate Chemical compound CCCCOCCOC(C)=O NQBXSWAWVZHKBZ-UHFFFAOYSA-N 0.000 claims description 3
- UPGSWASWQBLSKZ-UHFFFAOYSA-N 2-hexoxyethanol Chemical compound CCCCCCOCCO UPGSWASWQBLSKZ-UHFFFAOYSA-N 0.000 claims description 3
- QCDWFXQBSFUVSP-UHFFFAOYSA-N 2-phenoxyethanol Chemical compound OCCOC1=CC=CC=C1 QCDWFXQBSFUVSP-UHFFFAOYSA-N 0.000 claims description 3
- YEYKMVJDLWJFOA-UHFFFAOYSA-N 2-propoxyethanol Chemical compound CCCOCCO YEYKMVJDLWJFOA-UHFFFAOYSA-N 0.000 claims description 3
- VATRWWPJWVCZTA-UHFFFAOYSA-N 3-oxo-n-[2-(trifluoromethyl)phenyl]butanamide Chemical compound CC(=O)CC(=O)NC1=CC=CC=C1C(F)(F)F VATRWWPJWVCZTA-UHFFFAOYSA-N 0.000 claims description 3
- 229940028356 diethylene glycol monobutyl ether Drugs 0.000 claims description 3
- XXJWXESWEXIICW-UHFFFAOYSA-N diethylene glycol monoethyl ether Chemical compound CCOCCOCCO XXJWXESWEXIICW-UHFFFAOYSA-N 0.000 claims description 3
- 229940075557 diethylene glycol monoethyl ether Drugs 0.000 claims description 3
- UYAAVKFHBMJOJZ-UHFFFAOYSA-N diimidazo[1,3-b:1',3'-e]pyrazine-5,10-dione Chemical compound O=C1C2=CN=CN2C(=O)C2=CN=CN12 UYAAVKFHBMJOJZ-UHFFFAOYSA-N 0.000 claims description 3
- JCGNDDUYTRNOFT-UHFFFAOYSA-N oxolane-2,4-dione Chemical compound O=C1COC(=O)C1 JCGNDDUYTRNOFT-UHFFFAOYSA-N 0.000 claims description 3
- 229940116423 propylene glycol diacetate Drugs 0.000 claims description 3
- LLHKCFNBLRBOGN-UHFFFAOYSA-N propylene glycol methyl ether acetate Chemical compound COCC(C)OC(C)=O LLHKCFNBLRBOGN-UHFFFAOYSA-N 0.000 claims description 3
- JLGLQAWTXXGVEM-UHFFFAOYSA-N triethylene glycol monomethyl ether Chemical group COCCOCCOCCO JLGLQAWTXXGVEM-UHFFFAOYSA-N 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- NOOLISFMXDJSKH-UTLUCORTSA-N (+)-Neomenthol Chemical compound CC(C)[C@@H]1CC[C@@H](C)C[C@@H]1O NOOLISFMXDJSKH-UTLUCORTSA-N 0.000 claims description 2
- DTGKSKDOIYIVQL-WEDXCCLWSA-N (+)-borneol Chemical compound C1C[C@@]2(C)[C@@H](O)C[C@@H]1C2(C)C DTGKSKDOIYIVQL-WEDXCCLWSA-N 0.000 claims description 2
- REPVLJRCJUVQFA-UHFFFAOYSA-N (-)-isopinocampheol Natural products C1C(O)C(C)C2C(C)(C)C1C2 REPVLJRCJUVQFA-UHFFFAOYSA-N 0.000 claims description 2
- 239000001169 1-methyl-4-propan-2-ylcyclohexa-1,4-diene Substances 0.000 claims description 2
- NOOLISFMXDJSKH-UHFFFAOYSA-N DL-menthol Natural products CC(C)C1CCC(C)CC1O NOOLISFMXDJSKH-UHFFFAOYSA-N 0.000 claims description 2
- 239000005844 Thymol Substances 0.000 claims description 2
- 229940116229 borneol Drugs 0.000 claims description 2
- CKDOCTFBFTVPSN-UHFFFAOYSA-N borneol Natural products C1CC2(C)C(C)CC1C2(C)C CKDOCTFBFTVPSN-UHFFFAOYSA-N 0.000 claims description 2
- DTGKSKDOIYIVQL-UHFFFAOYSA-N dl-isoborneol Natural products C1CC2(C)C(O)CC1C2(C)C DTGKSKDOIYIVQL-UHFFFAOYSA-N 0.000 claims description 2
- 229940041616 menthol Drugs 0.000 claims description 2
- 150000007875 phellandrene derivatives Chemical class 0.000 claims description 2
- 229930006978 terpinene Natural products 0.000 claims description 2
- 150000003507 terpinene derivatives Chemical class 0.000 claims description 2
- 229960000790 thymol Drugs 0.000 claims description 2
- 125000000545 (4R)-limonene group Chemical group 0.000 claims 1
- HFPZCAJZSCWRBC-UHFFFAOYSA-N p-cymene Chemical compound CC(C)C1=CC=C(C)C=C1 HFPZCAJZSCWRBC-UHFFFAOYSA-N 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 7
- 239000000654 additive Substances 0.000 abstract description 6
- 230000000996 additive effect Effects 0.000 abstract description 6
- 238000013019 agitation Methods 0.000 description 17
- 230000008569 process Effects 0.000 description 11
- 239000007788 liquid Substances 0.000 description 8
- 238000007639 printing Methods 0.000 description 7
- 241001274613 Corvus frugilegus Species 0.000 description 5
- 239000012530 fluid Substances 0.000 description 4
- LYCAIKOWRPUZTN-UHFFFAOYSA-N ethylene glycol Natural products OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 238000005086 pumping Methods 0.000 description 3
- 238000010146 3D printing Methods 0.000 description 2
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 2
- 239000002033 PVDF binder Substances 0.000 description 2
- 238000004090 dissolution Methods 0.000 description 2
- 238000007429 general method Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 238000002604 ultrasonography Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- MQJKPEGWNLWLTK-UHFFFAOYSA-N Dapsone Chemical compound C1=CC(N)=CC=C1S(=O)(=O)C1=CC=C(N)C=C1 MQJKPEGWNLWLTK-UHFFFAOYSA-N 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000010028 chemical finishing Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 229910000366 copper(II) sulfate Inorganic materials 0.000 description 1
- JZCCFEFSEZPSOG-UHFFFAOYSA-L copper(II) sulfate pentahydrate Chemical compound O.O.O.O.O.[Cu+2].[O-]S([O-])(=O)=O JZCCFEFSEZPSOG-UHFFFAOYSA-L 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 235000001510 limonene Nutrition 0.000 description 1
- 229940087305 limonene Drugs 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000005063 solubilization Methods 0.000 description 1
- 230000007928 solubilization Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
Classifications
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/50—Solvents
- C11D7/5004—Organic solvents
- C11D7/5022—Organic solvents containing oxygen
-
- C11D2111/20—
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/22—Organic compounds
- C11D7/24—Hydrocarbons
- C11D7/248—Terpenes
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/22—Organic compounds
- C11D7/26—Organic compounds containing oxygen
- C11D7/261—Alcohols; Phenols
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/22—Organic compounds
- C11D7/26—Organic compounds containing oxygen
- C11D7/263—Ethers
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/0037—Production of three-dimensional images
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
- G03F7/30—Imagewise removal using liquid means
- G03F7/32—Liquid compositions therefor, e.g. developers
- G03F7/325—Non-aqueous compositions
Definitions
- the disclosure generally relates to fluidic chemical solutions and methods for removing unwanted support material and/or resin (hereinafter“SM/R”) from an object made by additive manufacturing techniques such as 3D printing. Fluidic chemical solutions and methods of using such solutions may involve contacting the object with the fluidic chemical solution.
- S/R unwanted support material and/or resin
- 3D printing is a process whereby a computer controlled device (e.g., a printer) creates an object through additive manufacturing.
- object refers to a 3D-printed object that is not in its desired final form.
- An object can be manufactured by stereolithography (SLA)“printing” techniques, and other methods known by those in the art.
- SLA stereolithography
- Commonly used additive manufacturing methods require additional material (“support material”) to be printed for the purpose of supporting portions of the object during printing.
- the support material also may be needed post-printing/pre-curing (or annealing). This support material buttresses the object to prevent issues like sagging.
- finishing refers to removing unwanted material from a 3D-printed object so as to produce a finished or semi-finished part. Finishing can include one or more processes, including, but not limited to, removing unwanted resin, removing unwanted metal powder, removing unwanted print material, and/or removing unwanted support material. In the 3-D printing industry, finishing may be referred to as “cleaning.”
- the support material itself can have a complex geometry and can also be extensive, because it may support the object at a plurality of locations. Additionally, because additive manufacturing prints an object in discrete layers, the surface finish of an object is often rough because edges of the layers do not always align with each other, thus creating a rough, bumpy outer surface. This outer surface is unappealing from a visual standpoint and creates stress concentrations, which could result in cracks during testing or use, and thus lead to a premature failure if the rough surface is not made smooth during finishing.
- IP A isopropanol
- Figure 1 A depicts a machine that can be used to finish a 3D-printed object with a finishing solution that is in keeping with the invention.
- Figure 1B is a cross-sectional view of the machine depicted in Figure 1 A.
- Figure 2 shows a flow diagram of a method of using a finishing solution that is in keeping with the invention.
- Figures 3 A and 3B are photos of an object (a rook) that was made by
- FIG. 3 A shows the object prior to application of a finishing solution that is in keeping with the invention.
- Figure 3B shows the object after two minutes of submersion in a finishing solution that is in keeping with the invention.
- Ranges of values are disclosed herein. The ranges set out a lower limit value
- LLV low voltage
- ULV upper limit value
- the LLV, ULV, and all values between the LLV and ULV are part of the range.
- the invention may be embodied as one or more finishing solutions capable of removing unwanted resin from a 3D printed stereolithography (SLA) object and/or weakening support material that was associated with the removed resin.
- SLA 3D printed stereolithography
- the resin is partially cured with the laser during the print process.
- the completely uncured resin is removed using a finishing solution formulated according to an embodiment of the present invention.
- the next step is a post-cure using a UV oven.
- the SM/R that was not cured may be dissolved by a finishing solution of an embodiment before the object is placed into an ultraviolet (“UV”) curing chamber for final curing.
- UV ultraviolet
- the term“support material” refers to material that is operatively arranged to support portions of an object during an additive manufacturing process to create the object, but which is unwanted once the manufacturing process is complete.
- the phrase“unwanted support material” includes unwanted resin.
- Unwanted SM/R can be the same material as the object which is being manufactured, or can be a different material.
- Materials that can be removed during finishing include, but are not limited to, Accura 25, Accura 48HTR, Accura 55, Accura 60, Accura ABS, Accura Bluestone, Accura ClearVue, Accura Extreme, Accura SL 5530, e-Stone, Figure 4 ELAST-BLK, Figure 4 ELAST-BLK 10, Figure 4 TOUGH-BLK 20, Figure 4 TOUGH-GRY 10, VisiJet Clear, VisiJet Flex, FORMLABS ® (e.g., Clear, White, Tough, Castable, Flexible, Dental SG, and the like) photopolymer resin, Carbon (CE, DPR 10, EPU 40, EPU 41, EPX, RPU 70, UMA 90, PR 25), Somos 9120, Somos Element, Somos EvoLVe, Somos PerForm, Somos ProtoGen 18420, Somos ProtoTerm, Somos Taurus, Somos Watershed, WaterCl ear Ultra, Somos NeXt, and the like.
- an unfinished 3D-printed object (or simply,“object”) may be subjected to a process to remove unwanted SM/R, and thereby provide a finished part.
- the object is placed in a tank that has been filled (e.g., filled at least partially) with a liquid finishing solution that is in keeping with the invention.
- the object may be completely or partially submerged in the finishing solution.
- the object While the object is in the finishing solution (e.g., submerged or at least partially submerged in the finishing solution), the object may be subjected to application of mechanical energy, such as agitation, abrasion, and/or heating in order to remove unwanted resin from the object.
- Mechanical energy agitation may occur by moving the liquid finishing solution (e.g., via a pump) and/or by using ultrasound.
- the object is subjected to a liquid spray.
- the object is placed in a chamber, and a pump is used to force the liquid finishing solution through one or more nozzles (i.e., spraying), which apply the finishing solution to the object and mechanically agitates the object.
- the liquid often includes chemical solvents to dissolve support material and/or unwanted resin, and thereby create a finished or nearly finished form of the object.
- Heat from a heat source may be used to maintain the finishing solution at a desired temperature. Under these conditions the support material may be removed thermally, chemically, mechanically or via a combination of two or more of these general methods.
- a finishing solution that is in keeping with the invention is an entirely (or almost entirely) organic solution for removing unwanted SM/R from an SLA 3D-printed object, build tray, or build plate.
- Such a finishing solution may comprise:
- a terpene in a finishing solution that is in keeping with the invention may aid in dissolving organics found in resins that are frequently used in SLA printing techniques.
- terpenes suitable for a finishing solution that is in keeping with the invention include, but are not limited to, D-limonene, dipentene, terpinenes, menthol, pinene, thymol, borneol, phellandrene, />-cymene, and combinations thereof.
- a finishing solution that is in keeping with the invention may be 20-50% by weight a terpene, including all 0.1% values and ranges therebetween (e.g., 40% by weight a terpene, such as, for example, D- limonene), relative to the total weight of the finishing solution.
- a finishing solution may contain one or more glycol ethers.
- a glycol ether in a finishing solution that is in keeping with the invention can aid in dissolving organics found in resins that are typically used in SLA printing techniques.
- Examples of glycol ethers suitable for a finishing solution include, but are not limited to, methoxytriglycol, ethoxytriglycol,
- butoxytriglycol diethylene glycol n-butyl ether acetate, diethylene glycol monobutyl ether, ethylene glycol n-butyl ether acetate, ethylene glycol monobutyl ether, diethylene glycol monoethyl ether, DOWANOLTMDPH 255, ethylene glycol phenyl ether, diethylene glycol monohexyl ether, ethylene glycol monohexyl ether, diethylene glycol monomethyl ether, ethylene glycol monopropyl ether, dipropylene glycol methyl ether, dipropylene glycol methyl ether, dipropylene glycol methyl ether acetate, dipropylene glycol n-butyl ether, propylene glycol diacetate, propylene glycol methyl ether, propylene glycol monomethyl ether acetate, propylene glycol n-butyl ether, propylene glycol phenyl ether, tripropylene glycol methyl
- a finishing solution that is in keeping with the invention may include 20-60% by weight a glycol ether, including all 0.1% values and ranges therebetween (e.g., 40% by weight a glycol ether, such as, for example, dipropylene glycol monomethyl ether), relative to the total weight of the finishing solution.
- a finishing solution that is in keeping with another embodiment of the invention may include one or more additional glycol ethers.
- the additional glycol ether may be 10-50% by weight, including all 0.1% values and ranges therebetween (e.g., 20% by weight additional glycol ether, such as, for example, ethylene glycol monobutyl ether), relative to the total weight of the finishing solution.
- the finishing solution can comprise:
- DPM dipropylene glycol monomethyl ether
- the finishing solution can comprise:
- the invention may be embodied as a method of using a finishing solution.
- the steps of such a method may be sufficient to remove unwanted SM/R from a 3D-printed object, build plate, or build tray.
- the method can comprise:
- Another method may comprise:
- finishing solution may be accomplished by submerging in the finishing solution all or part of the object that requires finishing.
- the word “submerged” refers to a situation where the object is submerged at a depth sufficient to cover the object or portion thereof that requires finishing.
- the finishing solution can be stored in a holding vessel/container/tank.
- Non-limiting examples of materials that the holding vessel/container/tank may be made of include stainless steel, glass, high density polyethylene, Teflon, Kalrez, Polyvinylidene Fluoride (PVDF), and the like.
- Agitation and/or vibration can be induced by methods such as, but are not limited to, sonication (e.g., via an ultrasonic transducer sending ultrasonic longitudinal waves into the finishing solution), a pump (e.g., using a pump to effect fluid movement), stirring, or a combination thereof.
- sonication e.g., via an ultrasonic transducer sending ultrasonic longitudinal waves into the finishing solution
- a pump e.g., using a pump to effect fluid movement
- stirring e.g., stirring, or a combination thereof.
- Sonication may be performed at a power up to and including 1750 W, including all 0.1 W values and ranges below 1750 W, where power may vary temporally, and at a frequency of 20-100 kHz, including all 0.1 kHz values and ranges therebetween. In a preferred example, the frequency is 40 kHz.
- Sonicating a finishing solution that is in keeping with the invention can agitate the finishing solution such that the finishing solution does not separate into distinct phases and/or such that a force is applied to the object, or to move the finishing solution. Applying a force to the object helps dislodge and/or dissolve unwanted SM/R.
- Such a finishing solution can be agitated for 1-60 minutes, including all 1 second values and ranges
- the ultrasonic waves may be provided at a selected first agitation frequency.
- the amplitude of the reflected ultrasonic waves may be detected by a sensor, and the amplitude of the reflected waves may be measured. Based on the measured amplitude, a second ultrasonic frequency may be selected, for example, using a database. Then ultrasound waves having the selected second ultrasonic frequency may be directed at the object. In this manner, the second ultrasonic frequency may be selected so as to optimally agitate.
- This process may be repeated until the detected amplitude indicates (e.g., indicates through sensor feedback) that a resonant frequency of unwanted SM/R has been reached.
- the resonant frequency of the remaining support material and/or unwanted resin may change, and so the process of selecting an ultrasonic agitation frequency may need to be repeated from time to time.
- the object may be removed from the tank and inspected to determine whether additional run-time is needed. Additional run-time may be needed if the object is “tacky” or too rough.
- Agitation by a pump can include pumping a finishing solution into a tank (28) containing the object.
- a pump may pump finishing solution into a tank (28) at a rate of 1-20 gallon/minute, including all 0.1 gallon/minute values and ranges therebetween.
- an equal amount of finishing solution may be made to flow out of the tank (28), over a weir (20) into an input tank (18), and then through a filter to a drain and back to the inlet of the pump.
- the finishing solution is pumped into the tank (28)
- the solution entering the tank mixes with the finishing solution that was already in the tank.
- a finishing solution may be agitated for 1-60 minutes, including all 1 second values and ranges therebetween, prior to the object being submerged and/or while the object is submerged. Agitation prior to the object being submerged aids in mixing the finishing solution. Agitation after the object is submerged assists in removing unwanted SM/R. Additionally, any other method to induce fluid movement may be suitable to induce such agitation (e.g., such as that induced by an ultrasonic generator (70)).
- Stirring of the finishing solution can be performed by the use of an impeller, mechanical stirrer, stir bar, or the like.
- a finishing solution can be agitated for 1-60 minutes, including all 1 second values and ranges therebetween, prior to the object being submerged and/or while the object is submerged.
- An object may be submerged (completely or partially) in a finishing solution that is in keeping with the invention and agitated during at least part of the submersion.
- An object may be submerged for a time sufficient to remove unwanted resin.
- the finishing solution may be agitated during the entire time of submersion or during part of the time that the object is submerged.
- the amount of time can be 1-60 minutes, including all 1 second values and ranges therebetween.
- the amount of time needed to remove the unwanted material from the object may depend on the geometry of the object. For example, more complicated geometries may require additional submersion time.
- an object can be adequately finished by submerging the object for a time that is between 1 and 30 minutes, including all 1 second values and ranges therebetween, and the finishing solution may be agitated for the entire duration of submersion or during part of the time that the object is submerged.
- Agitation of the finishing solution induced by stirring, a pump, and/or other methods, may create friction between the finishing solution and the object being finished, thereby assisting in removal of unwanted SM/R.
- Removal of the unwanted SM/R may be enhanced by ultrasonic transducers placed in the tank, such that the finishing solution vibrates, which is then imparted to the object.
- the ultrasonic transducers may be arranged on the side of the tank, and oriented tangential to the rotational flow of finishing solution in the tank. Such placement of the ultrasonic transducers achieves efficient agitation of the finishing solution and, thus, the submerged object.
- Sonication caused by ultrasonic transducers may enhance removal of support material by causing cavitation at the surface of the SM/R and the mechanical agitation caused by cavitation removes the SM/R. Such cavitation may be useful because cavitation enhances removal of unwanted SM/R.
- the finishing solution may be heated to or maintained at a temperature to increase the rate of solubilization of unwanted resin.
- the finishing solution may be kept at temperatures up to !3 lF° (including all 0.1 °F values and ranges between ambient and !3 lF°), before the object is submerged and/or while the object is submerged. At higher temperatures, e.g., higher than l3 lF°, appropriate handling precautions may be taken.
- a finishing solution that is in keeping with the invention can be recovered after the finishing operations are concluded.
- Steps for recovering the finishing solution may include allowing finishing solution to drip from the object back into a tank containing the finishing solution.
- the object may be rinsed with water or other suitable solvent. Such rinsing may be necessary to remove finishing solution that remains on the object.
- the object may be rough and tacky. Tackiness is related to uncured resin remaining on the surface. Such determination for roughness and/or tackiness may be determined by personal/operator preference. Such a determination can be made by personal/operator touch.
- a method such as that described herein may be repeated until the desired roughness and/or tackiness is/are achieved.
- the operator may determine that the object no longer requires additional finishing.
- a general method of use can include:
- Submersion in the finishing solution may weaken the support material substantially by facilitating dissolution of the unwanted resin.
- Fluid flow and ultrasonic agitation provide some mechanical force to loosen weakened support material, while also facilitating dissolution of uncured material (e.g., support material and/or resin).
- a method of using a finishing solution that is in keeping with the invention may be accomplished by using a machine manufactured by PostProcess Technologies, Inc.
- suitable machines include the DEMI ( Figure 1 shows a simplified schematic of a DEMI), CENTI, and FORTI. Additional agitation, such as from a pump, can reduce the amount of time needed to remove unwanted SM/R. ETsing such a machine can involve:
- finishing solution e.g., mixing may be performed by a pump and/or ultrasonic agitation
- the machine may be filled with finishing solution using an automated filling feature having a pump and reservoir.
- a liquid level sensor (19) may be positioned in the tank (28) or input tank (18). When signals from that sensor indicate the liquid level is too low, a pump may be caused to move fluid from the reservoir to the tank (28).
- the solution may be premixed before being added to the reservoir.
- the finishing solution may need to be mixed after the finishing solution has been added to the tank (28) in order to prevent separation of the components.
- a method of removing support material and/or unwanted resin may include placing a 3D-printed object within a tank of a machine, such as, for example, the machine depicted in Figure 1 A.
- a desired run time may be determined and/or selected, and the pump started so that the finishing solution is circulated through the tank by the pump.
- the method can involve:
- finishing solution may be applied to the object by spraying the finishing solution on the object.
- Spraying may be accomplished by using a machine capable of spraying the object or using a spray bottle (e.g., a bottle having an atomizer nozzle).
- finishing of the object can be performed on a bench top using a mixer (e.g., a stir plate and magnetic stir bar, or a mechanical stirrer) and a tank (e.g., a flask or beaker) to hold the finishing solution (and object being finished).
- the object may be placed in the tank holding the finishing solution that is in keeping with the invention. While the object is in that finishing solution, the mixer applies a force to the finishing solution, such that the finishing solution is moved within the tank, and also applies a force to the object, whereby unwanted SM/R is loosened from the object.
- a 3D-printed object (a rook, depicted in Figure 3 A) was printed using stereolithography (SLA) techniques and comprises Accura Clearvue resin.
- SLA stereolithography
Abstract
A finishing solution and a method for using the finishing solution for removing resin and/or support material from an object made by an additive manufacturing process, such as stereolithography (SLA), are disclosed. The finishing solution comprises 20-50% by weight of a terpene and 20-60% by weight of a glycol ether.
Description
CHEMICAL COMPOSITIONS FOR REMOVING RESIN FROM A 3D-PRINTED OBJECT AND METHODS OF MAKING AND USING SAME
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to ET.S. Ser. No. 62/730,944, filed September 13,
2018 and ET.S. Ser. No. 62/731,719, filed September 14, 2018, the entire disclosures of which are incorporated by reference herein.
FIELD OF THE DISCLOSURE
[0002] The disclosure generally relates to fluidic chemical solutions and methods for removing unwanted support material and/or resin (hereinafter“SM/R”) from an object made by additive manufacturing techniques such as 3D printing. Fluidic chemical solutions and methods of using such solutions may involve contacting the object with the fluidic chemical solution.
BACKGROUND OF THE DISCLOSURE
[0003] 3D printing is a process whereby a computer controlled device (e.g., a printer) creates an object through additive manufacturing. As used herein, unless otherwise indicated, the term“object” refers to a 3D-printed object that is not in its desired final form. An object can be manufactured by stereolithography (SLA)“printing” techniques, and other methods known by those in the art. Commonly used additive manufacturing methods require additional material (“support material”) to be printed for the purpose of supporting portions of the object during printing. The support material also may be needed post-printing/pre-curing (or annealing). This support material buttresses the object to prevent issues like sagging. After printing, the unwanted SM/R needs to be removed, and the processes that accomplish such removal are referred to as “finishing.” As used herein, unless otherwise indicated, the term“finishing” refers to removing unwanted material from a 3D-printed object so as to produce a finished or semi-finished part. Finishing can include one or more processes, including, but not limited to, removing unwanted resin, removing unwanted metal powder, removing unwanted print material, and/or removing unwanted support material. In the 3-D printing industry, finishing may be referred to as “cleaning.”
[0004] The support material itself can have a complex geometry and can also be extensive, because it may support the object at a plurality of locations. Additionally, because additive manufacturing prints an object in discrete layers, the surface finish of an object is often
rough because edges of the layers do not always align with each other, thus creating a rough, bumpy outer surface. This outer surface is unappealing from a visual standpoint and creates stress concentrations, which could result in cracks during testing or use, and thus lead to a premature failure if the rough surface is not made smooth during finishing.
[0005] Some finishing solutions are organic based and often contain isopropanol (IP A), which has a low flash point, and these solutions require precautions to work with. There has been a long felt need for a chemical finishing solution that overcomes such limitations.
BRIEF DESCRIPTION OF THE FIGURES
[0006] For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the
accompanying figures.
[0007] Figure 1 A depicts a machine that can be used to finish a 3D-printed object with a finishing solution that is in keeping with the invention.
[0008] Figure 1B is a cross-sectional view of the machine depicted in Figure 1 A.
[0009] The numbers in Figure 1A and Figure 1B identify: a support removal machine
(100), a control panel (12), cover doors (10), a front panel (8), a tank (28) holding a finishing solution that is in keeping with the invention, a weir (20), a computer (13), an input tank (18), a liquid level sensor (19), a wall (36), an ultrasonic generator (70), a tank manifold (14), and ultrasonic transducers (22).
[0010] Figure 2 shows a flow diagram of a method of using a finishing solution that is in keeping with the invention.
[0011] Figures 3 A and 3B are photos of an object (a rook) that was made by
stereolithography (SLA) comprising Accura Clearvue resin. Figure 3 A shows the object prior to application of a finishing solution that is in keeping with the invention. Figure 3B shows the object after two minutes of submersion in a finishing solution that is in keeping with the invention.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0012] Although the invention will be described in terms of certain embodiments, other embodiments, including embodiments that do not provide all of the benefits and features set
forth herein, are also within the scope of this disclosure. Various structural, logical, and process step changes may be made without departing from the scope of the invention.
[0013] Ranges of values are disclosed herein. The ranges set out a lower limit value
(“LLV”) and an upper limit value (“ULV”). The LLV, ULV, and all values between the LLV and ULV are part of the range.
[0014] The invention may be embodied as one or more finishing solutions capable of removing unwanted resin from a 3D printed stereolithography (SLA) object and/or weakening support material that was associated with the removed resin. With SLA, the resin is partially cured with the laser during the print process. Next, the completely uncured resin is removed using a finishing solution formulated according to an embodiment of the present invention. The next step is a post-cure using a UV oven. In other words, the SM/R that was not cured may be dissolved by a finishing solution of an embodiment before the object is placed into an ultraviolet (“UV”) curing chamber for final curing.
[0015] As used herein, unless otherwise indicated, the term“support material” refers to material that is operatively arranged to support portions of an object during an additive manufacturing process to create the object, but which is unwanted once the manufacturing process is complete. As used herein, the phrase“unwanted support material” includes unwanted resin. Unwanted SM/R can be the same material as the object which is being manufactured, or can be a different material. Materials that can be removed during finishing include, but are not limited to, Accura 25, Accura 48HTR, Accura 55, Accura 60, Accura ABS, Accura Bluestone, Accura ClearVue, Accura Extreme, Accura SL 5530, e-Stone, Figure 4 ELAST-BLK, Figure 4 ELAST-BLK 10, Figure 4 TOUGH-BLK 20, Figure 4 TOUGH-GRY 10, VisiJet Clear, VisiJet Flex, FORMLABS® (e.g., Clear, White, Tough, Castable, Flexible, Dental SG, and the like) photopolymer resin, Carbon (CE, DPR 10, EPU 40, EPU 41, EPX, RPU 70, UMA 90, PR 25), Somos 9120, Somos Element, Somos EvoLVe, Somos PerForm, Somos ProtoGen 18420, Somos ProtoTerm, Somos Taurus, Somos Watershed, WaterCl ear Ultra, Somos NeXt, and the like.
[0016] As used herein, unless otherwise indicated, the term“agitated” refers to effecting movement by an outside force. With regard to the finishing solution, non-limiting examples of agitation include moving finishing solution via a pump, stirring, using longitudinal waves at an ultrasonic frequency, or combinations thereof.
[0017] In a machine for removing support material, an unfinished 3D-printed object (or simply,“object”) may be subjected to a process to remove unwanted SM/R, and thereby provide a finished part. In one such process, the object is placed in a tank that has been filled (e.g., filled at least partially) with a liquid finishing solution that is in keeping with the invention. The object may be completely or partially submerged in the finishing solution. While the object is in the finishing solution (e.g., submerged or at least partially submerged in the finishing solution), the object may be subjected to application of mechanical energy, such as agitation, abrasion, and/or heating in order to remove unwanted resin from the object. Mechanical energy agitation may occur by moving the liquid finishing solution (e.g., via a pump) and/or by using ultrasound. In other such processes, the object is subjected to a liquid spray. In these processes, the object is placed in a chamber, and a pump is used to force the liquid finishing solution through one or more nozzles (i.e., spraying), which apply the finishing solution to the object and mechanically agitates the object. In submersion and spraying processes, the liquid often includes chemical solvents to dissolve support material and/or unwanted resin, and thereby create a finished or nearly finished form of the object. Heat from a heat source may be used to maintain the finishing solution at a desired temperature. Under these conditions the support material may be removed thermally, chemically, mechanically or via a combination of two or more of these general methods.
[0018] A finishing solution that is in keeping with the invention is an entirely (or almost entirely) organic solution for removing unwanted SM/R from an SLA 3D-printed object, build tray, or build plate. Such a finishing solution may comprise:
(a) 20-50% by weight of a terpene, including all 0.1% values and ranges therebetween; and
(b) 20-60% by weight of a glycol ether, including all 0.1% values and ranges therebetween; wherein the total percent by weight is 100.
[0019] A terpene in a finishing solution that is in keeping with the invention may aid in dissolving organics found in resins that are frequently used in SLA printing techniques.
Examples of terpenes suitable for a finishing solution that is in keeping with the invention include, but are not limited to, D-limonene, dipentene, terpinenes, menthol, pinene, thymol, borneol, phellandrene, />-cymene, and combinations thereof. For example, a finishing solution that is in keeping with the invention may be 20-50% by weight a terpene, including all 0.1%
values and ranges therebetween (e.g., 40% by weight a terpene, such as, for example, D- limonene), relative to the total weight of the finishing solution.
[0020] A finishing solution may contain one or more glycol ethers. A glycol ether in a finishing solution that is in keeping with the invention can aid in dissolving organics found in resins that are typically used in SLA printing techniques. Examples of glycol ethers suitable for a finishing solution include, but are not limited to, methoxytriglycol, ethoxytriglycol,
butoxytriglycol, diethylene glycol n-butyl ether acetate, diethylene glycol monobutyl ether, ethylene glycol n-butyl ether acetate, ethylene glycol monobutyl ether, diethylene glycol monoethyl ether, DOWANOL™DPH 255, ethylene glycol phenyl ether, diethylene glycol monohexyl ether, ethylene glycol monohexyl ether, diethylene glycol monomethyl ether, ethylene glycol monopropyl ether, dipropylene glycol methyl ether, dipropylene glycol methyl ether acetate, dipropylene glycol n-butyl ether, propylene glycol diacetate, propylene glycol methyl ether, propylene glycol monomethyl ether acetate, propylene glycol n-butyl ether, propylene glycol phenyl ether, tripropylene glycol methyl ether, tripropylene glycol n-butyl ether, dipropylene glycol dimethyl ether, and combinations thereof. For example, a finishing solution that is in keeping with the invention may include 20-60% by weight a glycol ether, including all 0.1% values and ranges therebetween (e.g., 40% by weight a glycol ether, such as, for example, dipropylene glycol monomethyl ether), relative to the total weight of the finishing solution. A finishing solution that is in keeping with another embodiment of the invention may include one or more additional glycol ethers. In an embodiment with more than one glycol ether, the additional glycol ether may be 10-50% by weight, including all 0.1% values and ranges therebetween (e.g., 20% by weight additional glycol ether, such as, for example, ethylene glycol monobutyl ether), relative to the total weight of the finishing solution.
[0021] For example, in an embodiment that includes more than one glycol ether, the finishing solution can comprise:
(a) 20-50% by weight D-limonene, including all 0.1% values and ranges therebetween;
(b) 20-60% by weight dipropylene glycol monomethyl ether (“DPM”), including all 0.1% values and ranges therebetween;
(c) 10-50% by weight ethylene glycol monobutyl ether (“EB”), including all 0.1% values and ranges therebetween.
In a more specific example, in an embodiment that includes more than one glycol ether, the finishing solution can comprise:
(a) 40% by weight D-limonene;
(b) 40% by weight DPM;
(c) 20% by weight EB.
[0022] The invention may be embodied as a method of using a finishing solution. The steps of such a method may be sufficient to remove unwanted SM/R from a 3D-printed object, build plate, or build tray. The method can comprise:
(a) applying (e.g., by submerging the object) a finishing solution of the present invention to an object or a portion thereof;
(b) agitating the finishing solution during at least part of the application; and
(c) removing the object from the finishing solution.
Another method may comprise:
(a) spraying an object or a portion thereof with a finishing solution, such as the solution described above; and
(b) removing the finishing solution from the object.
[0023] Application of the finishing solution may be accomplished by submerging in the finishing solution all or part of the object that requires finishing. When used herein, the word “submerged” refers to a situation where the object is submerged at a depth sufficient to cover the object or portion thereof that requires finishing. The finishing solution can be stored in a holding vessel/container/tank. Non-limiting examples of materials that the holding vessel/container/tank may be made of include stainless steel, glass, high density polyethylene, Teflon, Kalrez, Polyvinylidene Fluoride (PVDF), and the like.
[0024] Agitation and/or vibration can be induced by methods such as, but are not limited to, sonication (e.g., via an ultrasonic transducer sending ultrasonic longitudinal waves into the finishing solution), a pump (e.g., using a pump to effect fluid movement), stirring, or a combination thereof.
[0025] Sonication may be performed at a power up to and including 1750 W, including all 0.1 W values and ranges below 1750 W, where power may vary temporally, and at a frequency of 20-100 kHz, including all 0.1 kHz values and ranges therebetween. In a preferred example, the frequency is 40 kHz. Sonicating a finishing solution that is in keeping with the
invention can agitate the finishing solution such that the finishing solution does not separate into distinct phases and/or such that a force is applied to the object, or to move the finishing solution. Applying a force to the object helps dislodge and/or dissolve unwanted SM/R. Such a finishing solution can be agitated for 1-60 minutes, including all 1 second values and ranges
therebetween, prior to the object being submerged, and/or while the object is submerged.
[0026] The ultrasonic waves may be provided at a selected first agitation frequency.
When agitated by the first frequency, the amplitude of the reflected ultrasonic waves may be detected by a sensor, and the amplitude of the reflected waves may be measured. Based on the measured amplitude, a second ultrasonic frequency may be selected, for example, using a database. Then ultrasound waves having the selected second ultrasonic frequency may be directed at the object. In this manner, the second ultrasonic frequency may be selected so as to optimally agitate.
[0027] This process may be repeated until the detected amplitude indicates (e.g., indicates through sensor feedback) that a resonant frequency of unwanted SM/R has been reached. As support material and/or unwanted resin is removed, the resonant frequency of the remaining support material and/or unwanted resin may change, and so the process of selecting an ultrasonic agitation frequency may need to be repeated from time to time. When the desired run time has been reached, the object may be removed from the tank and inspected to determine whether additional run-time is needed. Additional run-time may be needed if the object is “tacky” or too rough.
[0028] Agitation by a pump can include pumping a finishing solution into a tank (28) containing the object. For example, a pump may pump finishing solution into a tank (28) at a rate of 1-20 gallon/minute, including all 0.1 gallon/minute values and ranges therebetween. By pumping finishing solution into the tank (28), an equal amount of finishing solution may be made to flow out of the tank (28), over a weir (20) into an input tank (18), and then through a filter to a drain and back to the inlet of the pump. As the finishing solution is pumped into the tank (28), the solution entering the tank mixes with the finishing solution that was already in the tank. A finishing solution may be agitated for 1-60 minutes, including all 1 second values and ranges therebetween, prior to the object being submerged and/or while the object is submerged. Agitation prior to the object being submerged aids in mixing the finishing solution. Agitation after the object is submerged assists in removing unwanted SM/R. Additionally, any other
method to induce fluid movement may be suitable to induce such agitation (e.g., such as that induced by an ultrasonic generator (70)).
[0029] Stirring of the finishing solution can be performed by the use of an impeller, mechanical stirrer, stir bar, or the like. A finishing solution can be agitated for 1-60 minutes, including all 1 second values and ranges therebetween, prior to the object being submerged and/or while the object is submerged.
[0030] An object may be submerged (completely or partially) in a finishing solution that is in keeping with the invention and agitated during at least part of the submersion. An object may be submerged for a time sufficient to remove unwanted resin. During such submersion, the finishing solution may be agitated during the entire time of submersion or during part of the time that the object is submerged. The amount of time can be 1-60 minutes, including all 1 second values and ranges therebetween. The amount of time needed to remove the unwanted material from the object may depend on the geometry of the object. For example, more complicated geometries may require additional submersion time. Often, an object can be adequately finished by submerging the object for a time that is between 1 and 30 minutes, including all 1 second values and ranges therebetween, and the finishing solution may be agitated for the entire duration of submersion or during part of the time that the object is submerged.
[0031] Agitation of the finishing solution induced by stirring, a pump, and/or other methods, may create friction between the finishing solution and the object being finished, thereby assisting in removal of unwanted SM/R. Removal of the unwanted SM/R may be enhanced by ultrasonic transducers placed in the tank, such that the finishing solution vibrates, which is then imparted to the object. In an example, the ultrasonic transducers may be arranged on the side of the tank, and oriented tangential to the rotational flow of finishing solution in the tank. Such placement of the ultrasonic transducers achieves efficient agitation of the finishing solution and, thus, the submerged object. Sonication caused by ultrasonic transducers may enhance removal of support material by causing cavitation at the surface of the SM/R and the mechanical agitation caused by cavitation removes the SM/R. Such cavitation may be useful because cavitation enhances removal of unwanted SM/R.
[0032] The finishing solution may be heated to or maintained at a temperature to increase the rate of solubilization of unwanted resin. For example, the finishing solution may be kept at temperatures up to !3 lF° (including all 0.1 °F values and ranges between ambient and !3 lF°),
before the object is submerged and/or while the object is submerged. At higher temperatures, e.g., higher than l3 lF°, appropriate handling precautions may be taken.
[0033] A finishing solution that is in keeping with the invention can be recovered after the finishing operations are concluded. Steps for recovering the finishing solution may include allowing finishing solution to drip from the object back into a tank containing the finishing solution. The object may be rinsed with water or other suitable solvent. Such rinsing may be necessary to remove finishing solution that remains on the object. Following application of the finishing solution, the object may be rough and tacky. Tackiness is related to uncured resin remaining on the surface. Such determination for roughness and/or tackiness may be determined by personal/operator preference. Such a determination can be made by personal/operator touch. When an operator determines that the object is too rough or too tacky, then a method such as that described herein may be repeated until the desired roughness and/or tackiness is/are achieved. When the object has the desired (or lack thereof) tackiness and roughness, the operator may determine that the object no longer requires additional finishing.
[0034] A general method of use can include:
(a) adding a finishing solution that is in keeping with the invention into a tank (28) of a
machine (e.g., a machine (100) used for finishing a 3-D printed object, such as that depicted in Figure 1 A and Figure 1B);
(b) using a heater that is arranged in the tank (28) to heat the finishing solution to a desired temperature;
(c) using a pump to move the finishing solution within the tank;
(d) using an ultrasonic transducer (22) arranged relative to the tank to provide ultrasonic longitudinal waves within the tank that agitate the finishing solution;
(e) contacting an object with the finishing solution for a desired time to remove unwanted SM/R from the object.
[0035] Submersion in the finishing solution may weaken the support material substantially by facilitating dissolution of the unwanted resin. Fluid flow and ultrasonic agitation provide some mechanical force to loosen weakened support material, while also facilitating dissolution of uncured material (e.g., support material and/or resin).
[0036] A method of using a finishing solution that is in keeping with the invention may be accomplished by using a machine manufactured by PostProcess Technologies, Inc. Examples
of suitable machines include the DEMI (Figure 1 shows a simplified schematic of a DEMI), CENTI, and FORTI. Additional agitation, such as from a pump, can reduce the amount of time needed to remove unwanted SM/R. ETsing such a machine can involve:
(a) adding a finishing solution that is in keeping with the invention into a machine (100) from the top of the machine by lifting a lid (or other suitable mechanism to cover the tank (28), such as the cover doors (10) depicted in Figure 1 A and Figure 1B) and pouring the finishing solution directly into a tank (28);
(b) mixing the finishing solution (e.g., mixing may be performed by a pump and/or ultrasonic agitation) sufficiently to ensure the finishing solution does not separate;
(c) heating the finishing solution via a submerged heater arranged in the tank, in order to heat the finishing solution to a desired temperature;
(d) pumping the finishing solution using a pump that may be arranged below the tank, in order to move the finishing solution through the tank and thereby agitate the solution and/or object.
[0037] The machine may be filled with finishing solution using an automated filling feature having a pump and reservoir. A liquid level sensor (19) may be positioned in the tank (28) or input tank (18). When signals from that sensor indicate the liquid level is too low, a pump may be caused to move fluid from the reservoir to the tank (28). The solution may be premixed before being added to the reservoir. In addition, the finishing solution may need to be mixed after the finishing solution has been added to the tank (28) in order to prevent separation of the components.
[0038] A method of removing support material and/or unwanted resin may include placing a 3D-printed object within a tank of a machine, such as, for example, the machine depicted in Figure 1 A. A desired run time may be determined and/or selected, and the pump started so that the finishing solution is circulated through the tank by the pump. The method can involve:
(a) placing an object in the finishing solution;
(b) circulating the finishing solution through the tank (28) to cause the object to rotate within the finishing solution; and
(c) directing ultrasonic energy waves at the object in the finishing solution so as to provide agitation.
[0039] In another example of the invention, the finishing solution may be applied to the object by spraying the finishing solution on the object. Spraying may be accomplished by using a machine capable of spraying the object or using a spray bottle (e.g., a bottle having an atomizer nozzle).
[0040] In another example, finishing of the object can be performed on a bench top using a mixer (e.g., a stir plate and magnetic stir bar, or a mechanical stirrer) and a tank (e.g., a flask or beaker) to hold the finishing solution (and object being finished). The object may be placed in the tank holding the finishing solution that is in keeping with the invention. While the object is in that finishing solution, the mixer applies a force to the finishing solution, such that the finishing solution is moved within the tank, and also applies a force to the object, whereby unwanted SM/R is loosened from the object.
[0041] The following example is presented to illustrate the invention. It is not intended to be limiting in any matter.
EXAMPLE 1
[0042] This example describes a method of using a finishing solution that is in keeping with the invention. A 3D-printed object (a rook, depicted in Figure 3 A) was printed using stereolithography (SLA) techniques and comprises Accura Clearvue resin.
[0043] The unfinished rook (Figure 3 A) was submerged in 500 mL of a finishing solution comprising:
40% by weight Ddimonene;
40% by weight dipropylene glycol monomethyl ether; and
20% by weight ethylene glycol monobutyl ether.
The solution was stirred for two minutes using a CORNING® stir plate (Model No. PC-420) set to speed 8. After the two minutes, the rook was removed from the finishing solution, rinsed with water, and dried. The finished rook is depicted in Figure 3B.
[0044] It will be appreciated that various aspects of the above-disclosed invention and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, and these are also intended to be encompassed by the invention. Although embodiments
of the invention have been described herein, the invention is not limited to such embodiments. The claims which follow are directed to the invention, and are intended to further describe the invention, but are not intended to limit the scope of the invention.
Claims
1. A finishing solution for removing resin and/or support material from an object, the finishing solution comprising:
20-50% by weight of a terpene; and
20-60% by weight of a glycol ether;
wherein the sum of the weight percent of the terpene and glycol ether does not exceed 100 weight percent.
2. The finishing solution of claim 1, wherein the terpene is selected from the group consisting of D-limonene, dipentene, terpinenes, menthol, pinene, thymol, borneol, phellandrene, p- cymene, and combinations thereof.
3. The finishing solution of claim 1, wherein the glycol ether is selected from the group consisting of methoxytriglycol, ethoxytriglycol, butoxytriglycol, diethylene glycol n-butyl ether acetate, diethylene glycol monobutyl ether, ethylene glycol n-butyl ether acetate, ethylene glycol monobutyl ether, diethylene glycol monoethyl ether, DOWANOL™DPH 255, ethylene glycol phenyl ether, diethylene glycol monohexyl ether, ethylene glycol monohexyl ether, diethylene glycol monomethyl ether, ethylene glycol monopropyl ether, dipropylene glycol methyl ether, dipropylene glycol methyl ether acetate, dipropylene glycol n-butyl ether, propylene glycol diacetate, propylene glycol methyl ether, propylene glycol monomethyl ether acetate, propylene glycol n-butyl ether, propylene glycol phenyl ether, tripropylene glycol methyl ether, tripropylene glycol n-butyl ether, dipropylene glycol dimethyl ether, and combinations thereof.
4. The finishing solution of claim 1, wherein:
the terpene is D-limonene; and
the glycol ether is dipropylene glycol monomethyl ether.
5. The finishing solution of claim 4, comprising 40% by weight D-limonene.
6. The finishing solution of claim 4, comprising 40% by weight dipropylene glycol monomethyl ether.
7. The finishing solution of claim 1 further comprising:
an additional different glycol ether.
8. The finishing solution of claim 7, wherein the additional different glycol ether is selected from the group consisting of methoxytriglycol, ethoxytriglycol, butoxytriglycol, diethylene glycol n-butyl ether acetate, diethylene glycol monobutyl ether, ethylene glycol n-butyl ether acetate, ethylene glycol monobutyl ether, diethylene glycol monoethyl ether, DOWANOL™ DPH 255, ethylene glycol phenyl ether, diethylene glycol monohexyl ether, ethylene glycol monohexyl ether, diethylene glycol monomethyl ether, ethylene glycol monopropyl ether, dipropylene glycol methyl ether, dipropylene glycol methyl ether acetate, dipropylene glycol n- butyl ether, propylene glycol diacetate, propylene glycol methyl ether, propylene glycol monomethyl ether acetate, propylene glycol n-butyl ether, propylene glycol phenyl ether, tripropylene glycol methyl ether, tripropylene glycol n-butyl ether, dipropylene glycol dimethyl ether, and combinations thereof.
9. The finishing solution of claim 7, comprising:
40% by weight D-limonene;
40% by weight dipropylene glycol monomethyl ether; and
20% by weight ethylene glycol monobutyl ether.
10. A method of removing resin and/or support material from an object comprising:
(i) submerging an object or a portion thereof in a finishing solution comprising 20-50% by weight of a terpene; and 20-60% by weight of a glycol ether; and
(ii) applying mechanical energy to the finishing solution during at least part of the submersion.
11. The method of claim 10 further comprising removing the object from the finishing solution.
12. The method of claim 10, wherein:
the terpene comprises D-limonene;
the glycol ether comprises dipropylene glycol monomethyl ether; and wherein the finishing solution further comprises:
an additional glycol ether, wherein the additional glycol ether comprises ethylene glycol monobutyl ether.
13. The method of claim 10, wherein the applying mechanical energy to the finishing solution is induced by sonication, a pump, stirring, or a combination thereof.
14. The method of claim 10, wherein the applying mechanical energy to the finishing solution occurs for 1-60 minutes prior to the object being submerged.
15. The method of claim 10, wherein the object or a portion thereof is submerged for 1-60 minutes, and the mechanical energy is applied to the finishing solution during the submersion.
16. The method of claim 10, further comprising:
(i) recovering finishing solution from the object by allowing the finishing solution to drip from the object into a tank, and/or
(ii) rinsing the object with water.
17. The method of claim 10, wherein the object is a manufactured object, build plate, or build tray.
18. The method of claim 10, wherein the finishing solution is at a temperature of 55-131 °F.
19. The method of claim 10, wherein the finishing solution is at a temperature of 55-127 °F.
20. A method of removing resin and/or support material from an object comprising:
(i) spraying an object or a portion thereof with a finishing solution comprising 20-50%
by weight of a terpene; and 20-60% by weight of a glycol ether; and (ii) removing the finishing solution from the object.
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US201862730944P | 2018-09-13 | 2018-09-13 | |
US62/730,944 | 2018-09-13 | ||
US201862731719P | 2018-09-14 | 2018-09-14 | |
US62/731,719 | 2018-09-14 |
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PCT/US2019/051094 WO2020056316A1 (en) | 2018-09-13 | 2019-09-13 | Chemical compositions for removing resin from a 3d-printed object and methods of making and using same |
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WO2021195320A1 (en) * | 2020-03-27 | 2021-09-30 | Postprocess Technologies, Inc. | Compositions for removing unwanted material from an object and methods of using such compositions |
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