WO2021126271A1 - Impression en trois dimensions avec des films de matériau de construction - Google Patents

Impression en trois dimensions avec des films de matériau de construction Download PDF

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Publication number
WO2021126271A1
WO2021126271A1 PCT/US2019/068120 US2019068120W WO2021126271A1 WO 2021126271 A1 WO2021126271 A1 WO 2021126271A1 US 2019068120 W US2019068120 W US 2019068120W WO 2021126271 A1 WO2021126271 A1 WO 2021126271A1
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WO
WIPO (PCT)
Prior art keywords
build material
material film
layers
adhesion promoting
film
Prior art date
Application number
PCT/US2019/068120
Other languages
English (en)
Inventor
Qin Liu
John C. Greeven
Jay Shields
Original Assignee
Hewlett-Packard Development Company, L.P.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hewlett-Packard Development Company, L.P. filed Critical Hewlett-Packard Development Company, L.P.
Priority to PCT/US2019/068120 priority Critical patent/WO2021126271A1/fr
Publication of WO2021126271A1 publication Critical patent/WO2021126271A1/fr

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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
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • 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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/147—Processes of additive manufacturing using only solid materials using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
    • 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

Definitions

  • 3D printing technology can change the product development cycle by allowing rapid creation of prototype models or even finished products. For example, several commercial sectors such as aviation and the medical industry, to name a few, have benefitted from rapid prototyping and/or the production of customized parts.
  • 3D printing There are various methods for 3D printing that have been developed, including heat-assisted extrusion, photo-polymerization, powder bed fusion (selective laser sintering), direct energy deposition, as well as others.
  • heat-assisted extrusion including photo-polymerization, powder bed fusion (selective laser sintering), direct energy deposition, as well as others.
  • powder bed fusion selective laser sintering
  • direct energy deposition as well as others.
  • FIG. 1 is a flowchart illustrating an example method for three- dimensional printing in accordance with the present disclosure
  • FIG. 2 schematically illustrates an example three-dimensional printing system in accordance with the present disclosure
  • FIG. 3 schematically illustrates an example device for three- dimensional printing in accordance with the present disclosure.
  • the present disclosure is drawn to a method of three-dimensional printing, three-dimensional printing systems, and a device for three-dimensional printing.
  • the method, system, and device presented herein can permit production of parts or printed articles, e.g., vehicle bumpers, car seats, recreation equipment, etc.
  • build material films can be individually stacked, bonded to one another, and selectively cut to define a volume of a three-dimensional object. This layer-by-layer process can be repeated until a three-dimensional object is formed.
  • the present disclosure is drawn to a method for three-dimensional printing.
  • the method can include iteratively applying individual layers of build material film that can have a thickness ranging from about 5 pm to about 1 cm, and iteratively adhering immediately adjacent and stacked individual layers together to become joined. Iteratively adhering can include applying an adhesion promoting agent, heat, electromagnetic energy, or a combination thereof to join the immediately adjacent and stacked individual layers. Additionally, based on a three-dimensional object model, the method can include iteratively and selectively cutting a single layer or a plurality of layers of the build material film after becoming joined to establish a portion of an exterior surface defining a volume of a three-dimensional object.
  • the iteratively applying of the adhesion promoting agent can be carried out based on the three-dimensional object model so that the adhesion promoting agent is applied within the volume of the three-dimensional object, and so that a portion or all of the build material film outside of the volume is not in contact with the adhesion promoting agent.
  • the build material film can be a solvent-softenable polymer film and the adhesion promoting agent can be applied and can include a solvent that can soften the solvent-softenable polymer film sufficient to cause two adjacent layers of the solvent-softenable polymer film to become chemically or physically joined together.
  • iteratively and selectively cutting can include cutting through the single layer of the build material film, but not cutting through a layer of the build material film stacked and immediately joined therewith.
  • the single layer can correspond with a most recently applied layer of the build material film.
  • iteratively and selectively cutting can include cutting through the plurality of layers of the build material film, but not cutting through all previously applied layers of the build material film, wherein the plurality of layers can include a most recently applied layer of the build material film.
  • individual layers of the build material film can have different thicknesses.
  • multiple immediately adjacent layers of the build material film can be applied in a biaxial orientation.
  • the method can further include applying pressure to a most recently applied layer of the build material film to assist with joining the most recently applied layer to an immediately and previously applied build material film layer.
  • the method can further include iteratively and selectively cutting a single layer or a plurality of layers of the build material film outside of the exterior surface that defines the volume of the three- dimensional object.
  • a three-dimensional printing system can include a build material film that can have a thickness ranging from about 5 pm to about 1 cm, an adhesion promoting agent to join immediately adjacent and stacked individual layers of the build material film together, a fluid ejector to iteratively apply the adhesion promoting agent to individual layers of the build material film that are advanced, and a cutter to iteratively and selectively cut a single layer or a plurality of layers of the build material film after becoming joined by the adhesion promoting agent as well as to establish an exterior surface defining a volume of a three-dimensional object.
  • the build material film can be a polymer film that can be reinforced with fiber including glass fiber, carbon fiber, polyaramid fiber, or a combination thereof.
  • the system can further include a pressure roller, pressure plates, or a combination thereof to apply pressure to the build material film after individual layers of the build material film have been joined together with the adhesion promoting agent.
  • a device for three-dimensional printing can include a film-advancement mechanism to advance a build material film; a printer support to receive build material film advanced by the film-advancement mechanism; a fluid ejector coupled or coupleable to an adhesion promoting agent to iteratively apply the adhesion promoting agent to individual layers of the build material film when advanced, a heating applicator to apply heat to individual layers of the build material film when advanced, or both to cause immediately adjacent individual layers of the build material film to become joined together; and a cutter to iteratively and selectively cut a single layer or a plurality of layers of the build material film after becoming joined by the adhesion promoting agent as well as to establish an exterior surface defining a volume of a three-dimensional object.
  • the device can further include a pressure applicator to contribute to joining immediately adjacent and stacked build material film layers together in conjunction with application of an adhesion promoting agent, heat, or both an adhesion promoting agent and heat.
  • the build material film can be in the form of a roll of the build material film and the film- advancement mechanism can be a roll-to-roll advancement mechanism, or the build material film can be in the form of a stack of build material film sheets and the film-advancement mechanism is a sheet advancement mechanism.
  • the method can include iteratively applying 110 individual layers of build material film where the individual layers can independently have a thickness ranging from about 5 pm to about 1 cm.
  • the method can further include iteratively adhering 120 immediately adjacent and stacked individual layers together to become joined.
  • the iteratively adhering can include applying an adhesion promoting agent to join the immediately adjacent and stacked individual layers, applying heat to join the immediately adjacent and stacked individual layers, applying electromagnetic energy to join the immediately adjacent and stacked individual layers, or applying a combination thereof.
  • the method can further include based on a three-dimensional object model, iteratively and selectively cutting 130 a single layer or a plurality of layers of the build material film after becoming joined to establish a portion of an exterior surface defining a volume of a three-dimensional object.
  • iteratively and selectively cutting can indicate that cutting can occur after every application layer or periodically after multiple layers of build material film are joined to one another. Iteratively and selectively cutting, however, does not indicate cutting through an entire stack of joined layers to cut a three-dimensional object at one time. Iteratively and selectively cutting, in one example, can include cutting contour lines of the three-dimensional object at individual build material layers, or after a few layers, e.g., 2 to about 5, are joined together.
  • individual layers can be cut after being joined with the previously applied layer, which is iteratively repeated.
  • multiple layers can be cut together in some examples.
  • the applying of individual layers of a build material film can include advancing a sheet of build material film or a portion of a roll of build material film over a print area, such as a print platform, printer support, etc., of a printing device.
  • the print area can be the location where build material layers are stacked, adhered together, and cut.
  • the print area can be at a single location, or can define multiple locations or stations where various actions occur.
  • Build material film can be advanced for use in the build based on the configuration of the build material film.
  • a roll of build material film can be advanced and joined a portion at a time, then cut, and then additional film “behind” it in the roll can be advanced for the next layer of application, joining, and cutting.
  • a stack of build material film “sheets” can likewise be used where a sheet of material is used, followed by advancement of the next sheet of material (for joining and cutting), and so forth.
  • a hybrid system where a portion of a sheet is used, and then another portion of the same sheet is advanced for the next layer, etc., followed by advancement of a new sheet once the prior sheet has been sufficiently spent.
  • an individual layer of the build material film can then be treated to permit adhesion of the individual layer to an adjacent layer of a build material film.
  • treatment can include applying an adhesion promoting agent.
  • the adhesion promoting agent can include a solvent, an adhesive, and/or an electromagnetic radiation absorber, for example.
  • the build material film can include a solvent-softenable polymer film and the adhesion promoting agent can include a solvent that can soften the solvent-softenable polymer film such that two adjacent layers of solvent-softenable polymer film can become chemically or physically joined to one another.
  • Example films and solvents that can be used include those used for the solvent-welding of plastic materials.
  • the treatment can include applying an adhesion promoting agent with an electromagnetic radiation absorber therein.
  • electromagnetic energy (ultraviolet, infrared, visible light, microwave, etc.) can be used to excite the electromagnetic radiation absorber, which would locally generate heat at the build material film to which the adhesion promoting agent was applied.
  • the electromagnetic radiation absorber along with the electromagnetic energy applied suitable to excite the electromagnetic radiation absorber to generate heat, can provide a temperature boosting capacity to increase a temperature of the build material film where the electromagnetic radiation absorber was applied.
  • heat generated at the electromagnetic energy absorber can be applied and can melt a surface of a layer of the build material film at the interface, so that physical fusion can occur from layer to layer.
  • Heat can be applied so that a bulk of an individual layer of build material film remains below the softening point or melting point of the build material film and the temperature does not adversely affect the shape of the object being built.
  • heat can be used to raise the temperature to near a temperature where build material film can be heat fused together, and then electromagnetic energy can be applied to cause the electromagnetic radiation absorber to heat the temperature further (enough to cause film-to-film heat fusion).
  • the electromagnetic radiation absorber and associated electromagnetic energy source
  • treatment can include applying heat to soften a surface of a build material film such that an adjacent layer (already positioned therebeneath and/or another layer that is to be subsequently applied) can be physically heat-fused to the individual layer of build material film that was heated (at its surface).
  • Heat can be applied at a temperature that can permit a surface of a build material film to melt so that physical fusion can occur from layer to layer while the bulk of an individual layer of build material film remains below the softening point or melting point of the build material film.
  • heat can be applied to exceed the softening point, but not the melting point.
  • heat can be applied to exceed the melting point, provided the temperature does not adversely affect the shape of the object being built.
  • the method can include iteratively and selectively cutting a single layer or a plurality of layers of the build material film outside of the exterior surface that defines the volume of the three- dimensional object so that the areas outside of the volume of the object can be removed, e.g., relief cuts radiating or otherwise connecting the outer dimension of the object and the edge of the build material film can be used to remove the waste area of film that does not become part of the object.
  • relief cuts can be used with other adhesion protocols other than the application of heat as well.
  • heat can be used in conjunction with the application of adhesion promoting agent(s) described previously.
  • heat can be used to bring the film to near its temperature for heat fusing or joining adjacent build material films, and then an adhesion promoting agent with electromagnetic radiation absorber can be selectively applied to allow for electromagnetic energy to boost the temperature to a suitable film-to-film fusing temperature, leaving areas outside where the adhesion promoting agent was printed unfused.
  • melting point can refer to the temperature at which a build material film transitions from a crystalline phase to a pliable and/or amorphous phase. Some build material films do not have a definite melting point perse, but rather have a range of temperatures over which the film softens.
  • the “softening point,” as used herein, can refer to the temperature at which an outer surface of a build material film softens sufficiently to become joined with an adjacently applied build material film (either previously or immediately thereafter or both).
  • adhesion promoting agent can be applied within a volume of the three-dimensional object so that a portion or all of the build material film outside of the volume of the three-dimensional object is not in contact with the adhesion promoting agent.
  • applying the adhesion promoting agent and/or heat can include indiscriminate application such that the adhesion promoting agent can be applied within and outside of a volume of the three- dimensional object.
  • adhering the build material film layers together can include both selective application of adhesion promoting agent as well as indiscriminate application of heat.
  • an adhesion promoting agent including an electromagnetic radiation absorber can be selectively applied within a volume of a three-dimensional object and heat can be indiscriminately applied over the individual build material film layer. Portions of the layer without the adhesion promoting agent applied thereto may not reach the same temperature and may not soften.
  • an additional individual layer of a build material film can be applied over the area of the build material film with the adhesion promoting agent and/or heat applied thereto, such that these adjacent individual layers (sandwiching the adhesion promoting agent, when present) become joined together chemically, physically, or both.
  • the additional (or next) individual layer applied can have the same or different thickness and/or can be the same or a different material relative to the build material film previously applied. Adjusting a thickness of individual layers of the build material film can minimize a quantity of layers in a three-dimensional object.
  • individual layers of the build material film can be applied in a multi- axial orientation, such that a grain of individual layers can have differing directions.
  • the multi-axial orientation may be a biaxial orientation with orthogonally oriented build material film grains positioned in alternating manner, e.g., periodically alternating or alternating every layer. This type of orientation or other multi-axial oriented build material film stacks can increase a tensile strength of a three-dimensional object.
  • iteratively and selectively cutting can include cutting through a single layer of the build material film or through multiple layers of the build material film. Cutting after adhering layers can minimize alignment concerns that would be present if the upper layer was pre-cut before application.
  • iteratively and selectively cutting can include cutting through a single layer of build material film and not cutting through a layer of the build material film stacked and immediately joined therewith.
  • iteratively and selectively cutting can include cutting through multiple adjacent individual layers of build material films.
  • iteratively and selectively cutting can include cutting through a plurality of layers of the build material film, but not cutting through all previously applied layers of the build material film.
  • the method can further include applying pressure to a most recently applied layer of build material film to assist with joining the most recently applied layer to an immediately and previously applied layer of build material film. Applying pressure can occur after adding an upper layer of a build material film and prior to cutting, after cutting, or after adding an upper layer of a build material and after cutting.
  • the method can further include cutting a single layer or a plurality of layers of the build material film outside of the exterior surface that defines the volume of the three-dimensional object. These outside cuts can allow for ease in removing excess build material film from an area around the three-dimensional object. In some examples, the excess build material film can be left in place during printing which can permit the excess build material film to act as a support for the three-dimensional object during printing.
  • excess build material film can be removed following cutting.
  • the excess build material film can be removed by raising the three- dimensional object therefrom.
  • excess build material film can be removed by physically removing and/or air blasting the film therefrom.
  • a three-dimensional printing system 200 as illustrated in FIG. 2 can include a build material film 210 that can have a thickness ranging from about 5 pm to about 1 cm, an adhesion promoting agent 220 to join immediately adjacent and stacked individual layers of the build material film together, a fluid ejector 230 to iteratively apply the adhesion promoting agent to individual layers of the build material film, and a cutter 240 to iteratively and selectively cut a single layer or a plurality of layers of the build material film after becoming joined by the adhesion promoting agent, as well as to establish an exterior surface defining a volume of a three-dimensional object.
  • a build material film 210 that can have a thickness ranging from about 5 pm to about 1 cm
  • an adhesion promoting agent 220 to join immediately adjacent and stacked individual layers of the build material film together
  • a fluid ejector 230 to iteratively apply the adhesion promoting agent to individual layers of the build material film
  • a cutter 240 to iteratively
  • the build material film shown is provided from a supply roll 212A, which can be roll-to-roll, or can be a single roll of material that is advanced, fused to adjacently stacked build material sheets, and repeated.
  • the supply of build material film can be in the form of sheets 212B, 212C of build material film, with individual sheets being used for a single layer or for a few layers, and then a new sheet advanced thereon to continue with the build.
  • the thickness of the build material film from these three sources is shown as different, illustrating that there can be multiple thicknesses used in a single build or a build can use a given thickness depending on the resolution goals of the three-dimensional object.
  • a three-dimensional printing device 300 is illustrated in FIG. 3.
  • the device can include a film-advancement mechanism 310 to advance a build material film 210 (sheets, rolls, etc.), a printer support 320 to receive the build material film advanced by the film-advancement mechanism, a fluid ejector 230 coupled or coupleable to an adhesion promoting agent 220 to iteratively apply the adhesion promoting agent to individual layers of the build material film, an energy source applicator 350 to apply energy (e) in the form of heat, electromagnetic energy, and/or some other energy source suitable for assisting with the fusing build material film layers together when advanced, and a cutter 240 to iteratively and selectively cut a single layer or a plurality of layers of the build material film after becoming joined.
  • various device components are supported by a frame 305, which can be a printer chassis with supports and carriage tracks or bars, or supports other movements of the various device components, for example.
  • the build material film 210 can be supported by a printer support 320 (or other support).
  • the support can be dropped by a thickness (x) of the build material film (or based on some other metric about how far to drop the support).
  • the cutter 240 and/or the fluid ejector 230 can be raised a similar distance. Maintaining or adjusting the spacing between the build material film and the cutter/fluid ejector(s) can, in another example, be by a combination of both lowering the support and raising the cutter/fluid ejector(s), etc.
  • the three-dimensional printing device 300 can further include an energy source 350, which can emit energy (e) toward the build material film in the form of heat, electromagnetic energy, etc., as appropriate for a given printing system.
  • the energy source can be in the form of heating plates, heating rollers, pressure roller, pressure plates, and/or a combination thereof.
  • a pressure roller and/or pressure plates can be heated.
  • the heat source if present, can be in the form of radiant heat or some other heat application technology. With respect to the pressure roller and/or plates, these can be used, for example, to apply pressure to a build material film after individual layers of the build material film have been joined together by an adhesion promoting agent and/or heat.
  • the pressure applicator if present, can contribute to joining the immediately adjacent and stacked build material film layers together in conjunction with application of an adhesion promoting agent, heat, or both.
  • the pressure applicator can apply a pressure ranging from about 0 psi to about 100 psi to build material film layers.
  • the system can also include a quenching applicator, such as a quenching roller(s), a quenching plate(s), or a combination thereof. These quenching applicators, if present, can cool a layer of build material faster than the build material layer would cool with the use of the quenching applicators.
  • the printer support 320 can be sized and shaped according to the three-dimensional objects intended to be printed therefrom.
  • a large printer support can be included on devices intended for printing industrial parts, while a smaller printer support can be included on devices intended for printing objects that are sized to be carried by an individual.
  • the size and shape of a printer support is not particularly limited.
  • the printer support can be configured to permit vertical movement.
  • the printer support could drop in vertical height to allow a subsequent individual layer of build material film to be applied thereto.
  • the printer support can be stationary.
  • a printer support can also include a securing feature, such as a vacuum, fastener, an adherent, or the like for securing a build material film to the build platform during printing.
  • the fluid ejector 230 can be any type of printing apparatus capable of selectively applying an adhesion promoting agent 220.
  • the fluid ejector can include an inkjet applicator (thermal, piezo, etc.), a sprayer, a dropper, or the like.
  • the fluid ejector can include an inkjet applicator.
  • the energy source 350 can be a heat source, an electromagnetic energy source, or the like.
  • a heating applicator can include a digital heater, hot tube furnace, hot air gun, a heat lamp, etc.
  • the heating applicator can be used to raise a temperature of the build material film.
  • a temperature range of heat provided by the heat source can vary; however, in some examples, the heat provided can range from about 100 °F to about 700 °F or from about 150 °F to about 500 °F.
  • the heat source can apply a temperature that can be at or below a softening temperature or melting temperature, or above the softening temperature or melting temperature of the build material film, depending on the nature of the build.
  • the temperature applied by the heat source may be lower than if using heat alone.
  • the energy source can be an electromagnetic energy source, such as a UV lamp, an IR lamp, a UV-LED source, an IR-LED source, a narrow band LED visible light source, etc.
  • the heat source can include a digital heater.
  • the cutter can include a mechanical cutter, a laser cutter, or both, and can be used to establish an exterior surface defining a volume of a three- dimensional object 400.
  • the cutter can include a knife, a blade, or the like.
  • the cutter can include a laser.
  • the cutter can be software controlled to permit precise cutting depths such that individual layers of build material film can be cut while layers of build material film adjacent thereto can remain uncut.
  • the cutter can be controllable along various axes relative to the major surface of the print material film, such as with x-axis, y- axis, and z-axis maneuverability.
  • the build material film can include any film that can be adhered to itself by an adhesion promoting agent and/or heat.
  • the build material film can exclude paper.
  • the build material film can include natural polymer films, synthetic polymer films, biological films, composite films/sheets, preformed thin sheets, honey comb materials, lattices, laminated glass sheet (e.g. windshield glass), metal foils, ceramic sheets (green ceramic), or a combination thereof.
  • a build material film can include a polymer film.
  • the polymer film can be semi-crystalline, amorphous, B-staged crosslinked film, or the like.
  • Examples of polymer films can include films of polymers of acrylonitrile butadiene styrene, acetal, acrylic, polyacrylonitrile, polymethyl methacrylate, polycarbonate, polystyrene, polyvinyl butyral, polyethylene, polypropylene, polyamide (nylon 6, nylon 12, nylon 66 and the like), polyoxymethylene, polyester, polyethylene terephthalate, polybutylene terephthalate, polyether ether ketone, polyphenylene sulfide, polysulfone, polyphenylene oxide, polysulfone, polyphenylsulfone, polyetherimide, polyamide- imide, polyphenylene sulfide, polyether ether ketone, or a combination thereof.
  • the build material film can include B-stage crosslinked epoxy, B-stage silicone, or the like.
  • B-stage materials can include MasterBond® (MasterBond Inc. USA) and Synder (Polymer Systems Technology Ltd. UK).
  • the build material film can be a reinforced film.
  • the reinforcement can include the addition of particles, continuous fibers, discontinuous fibers, fabric, or the like.
  • reinforced films can include build material films reinforced with minerals, talc, clay, glass, carbon, polyaramid, or the like.
  • the reinforcement can be added to the build material film at a weight range from about 5 wt% to about 80 wt%, from about 15 wt% to about 50 wt%, or from about 15 wt% to about 40 wt%.
  • a thickness of the build material film can also vary. In an example, a build material film can have a thickness ranging from about 5 pm to about 1 cm.
  • a build material film can have a thickness that can range from about 10 pm to about 1 mm, from about 50 pm to about 500 pm, from about 500 pm to about 1 cm, from about 1 mm to about 1 cm, or from about 100 pm to about 1 cm.
  • Thinner build material films can be more useful when manufacturing three-dimensional objects with varying outer dimensions and high resolution exterior surfaces. Thicker build material films can be more useful in manufacturing portions of three-dimensional objects with less stepping, e.g. few exterior surface changes in diameter between the individual layers and/or when printing larger sized parts, such as car bumpers, in a short period of time, less than about 24 hours.
  • thicker build material films can be used in combination with thinner build material films when printing a three-dimensional object.
  • thinner and thinner are relative terms and compare a thickness of an individual layer of a build material film to a thickness of another individual layer of a build material film. For example, thicker build material films can be applied in areas where less stepping occurs and thinner build material films can be applied in areas where there is more stepping.
  • a build material film can be in the form of individual sheets or on a roll. Sheets of build material films can, in one example, be selectively sized and shaped to minimize an amount of excess build material film that can be cut away from a layer of a three-dimensional object. In another example, individual sheets in a stack of sheets can all be similarly sized, and excess build material film can be left in place during printing and can be used as a support structure for the individual build material layers.
  • the adhesion promoting agent can be a jettable fluid that carries an adhesion promoting compound, or which is an adhesion promoting compound.
  • an organic co-solvent may be an adhesion promoting compound of a particular build material film in that the organic co-solvent acts to soften the build material film for fusion to another layer of film.
  • the adhesion promoting compound could be a dissolved or dispersed compound that is carried by a liquid vehicle of water and/or organic co-solvent (and in some instances other ingredients such as surfactant, biocide, etc.).
  • the adhesion promoting compound can be an electromagnetic energy absorber, an adhesive compound, or some other material useful for joining the build material film layers together.
  • the co-solvent can be selected for the specific build material film being used.
  • Example organic co solvents can include n-octane, n-dodecane, methylcyclohexane, benzene, toluene, naphthalene, o-xylene, ethyl benzene, p-diethyl benzene, chloromethane, methylene chloride, 1 ,1-dichloroethylene, 1 ,1-dichloroethane, trichloroethylene, carbon tetrachloride, chlorobenzene, o-dichlorobenzene, 1 ,4- dioxane, dibenzyl ether, methyl ethyl ketone, acetophenone, methyl isobutyl ketone, methyl isoamyl ketone
  • the organic co solvent can include acetone, cyclohexanone, tetrahydrofuran, ethanol, ethyl acetate, h,h-dimethylformamide, dimethylsulfoxide, a combination thereof, or the like.
  • Certain organic co-solvents for example, can soften build material films of polymethyl methacrylate, polyvinyl chloride, or a combination thereof.
  • Example pairings of or organic co-solvents and build material films that can be paired to promote softening of the film and adhesion of stacked adjacent layers of the film include polystyrene and acetone, polymethylmethacrylate and n,n- dimethylformamide, polyvinyl chloride and tetrahydrofuran, or polyamides and m- cresol.
  • the adhesion promoting agent can include jettable adhesives.
  • jettable adhesives can include cyanoacrylate, acrylate, acrylate ester, epoxies, urethanes, dissolved polymers of the same build materials with the same or lower molecular weight, reactive compounds, or a combination thereof.
  • the jettable adhesive can be a multi-part adhesive, where multiple components interact once contacted with one another, or a UV curable adhesive.
  • the adhesion promoting agent can include an electromagnetic radiation absorber.
  • the electromagnetic radiation absorber can absorb and convert electromagnetic energy to thermal energy.
  • the electromagnetic radiation absorber can be, for example, an infrared-absorbing colorant, a near-infrared-absorbing colorant, or a carbon black pigment.
  • Infrared absorbing compounds can extend from the nominal red edge of the visible spectrum at 700 nm up to 1mm, but more particularly, the infrared absorbing compounds can be in the range of about 800 nm to 1400 nm to convert absorbed light energy to thermal energy. Similar characteristics can be achieved using near-infrared compounds within the range of 950 nm to 1150 nm, for example.
  • Infrared compounds as an electromagnetic radiation absorber can have substantially no impact on the apparent color of the adhesion promoting agent. This allows the formulation of colorless jettable fluids which will not impart any visible color to the part.
  • Example near-infrared compounds that can be used include near-infrared dyes manufactured by HW Sands Corporation: SDA 1906 (Amax absorption 993 nm), SDA 3755 (A ma x absorption 1049 nm), and SDA 7630 (Amax absorption 1070 nm), as well as Ni-dithiolene-based compounds with very low absorption in visible light range, e.g., very low absorbance from 400 nm to 700 nm.
  • Black jettable fluids can have high absorbance within the visible spectrum (and are usually considered to have a broad absorbance spectrum), so depending on the desired result (e.g., black or colorless with the option to add colorant) appropriate absorbers can be selected accordingly.
  • electromagnetic radiation absorbers that can be used that have a broader absorption spectrum in the visible range, but which are not black.
  • Examples can include tetraphenyldiamine-based water-soluble near- infrared dyes, cyanine-based water-soluble near-infrared dyes, and dithiolene- based water-soluble near-infrared dyes.
  • the electromagnetic radiation absorber can provide a temperature boosting capacity sufficient to increase the temperature of the build material film above the melting or softening point of the film.
  • the electromagnetic radiation absorber can be dispersed in an aqueous liquid vehicle at from about 0.5 wt% to about 30 wt%, from about 5 wt% to about 25 wt%, or from about 1 wt% to about 20 wt%.
  • the adhesion promoting agent can further include an aqueous liquid vehicle to enhance jettability; however, not all adhesion promoting agents include an aqueous liquid vehicle.
  • the aqueous liquid vehicle when present, can include water as a major solvent, e.g., the solvent present at the highest concentration when compared to other co-solvents. In an example, water can be deionized.
  • An amount of water in the aqueous liquid vehicle can range from about 20 wt% to about 98 wt%, from about 40 wt% to about 95 wt%, from about 65 wt% to about 95 wt%, from about 70 wt% to about 98 wt%, or from about 80 to about 98 wt%.
  • the aqueous liquid vehicle can further include from about 1 wt% to about 50 wt%, from about 1 wt% to about 25 wt%, or from about 15 wt% to about 35 wt% of liquid components other than water.
  • the other liquid components can include organic co-solvents, surfactants, additives that inhibits growth of harmful microorganisms, viscosity modifiers, pH adjuster, sequestering agents, preservatives, and the like.
  • the liquid vehicle can consist essentially of water, organic co-solvent, and surfactant.
  • an organic co-solvent may be a softener for the build material film and/or may be added in for a different purpose, e.g., jettability, jetting reliability, decap performance, viscosity modification, etc.
  • Classes of co-solvents that can be used can include organic co-solvents including aliphatic alcohols, aromatic alcohols, diols, glycol ethers, polyglycol ethers, caprolactams, formamides, acetamides, and C3 to C150 alcohols.
  • Examples of such compounds can include primary aliphatic alcohols, secondary aliphatic alcohols, 1 ,2-alcohols, 1 ,3-alcohols, 1 ,5-alcohols, ethylene glycol alkyl ethers, propylene glycol alkyl ethers, higher homologs (C6-C12) of polyethylene glycol alkyl ethers, N-alkyl caprolactams, unsubstituted caprolactams, both substituted and unsubstituted formamides, both substituted and unsubstituted acetamides, and the like.
  • co-solvents act as a temperature reducing plasticizer for a specific build material film, some of these other co solvents can be considered to be applicable in that context.
  • the aqueous liquid vehicle can further include non-ionic, cationic, and/or anionic surfactant ranging from 0.01 wt% to 20 wt%, if present.
  • Example surfactants can include alkyl polyethylene oxides, alkyl phenyl polyethylene oxides, polyethylene oxide block copolymers, acetylenic polyethylene oxides, polyethylene oxide (di)esters, polyethylene oxide amines, protonated polyethylene oxide amines, protonated polyethylene oxide amides, dimethicone copolyols, substituted amine oxides, or the like.
  • surfactants can include, but are not limited to, TERGITOL ® TMN-6, TERGITOL ® 15S7, TERGITOL ® 15S9, LEG-1 , LEG-7; TritonTM X-100, and TritonTM X-405 all available from The Dow Chemical Company (USA)).
  • the amount of surfactant added to the formulation of this disclosure may range from 0.01 wt% to 20 wt%.
  • Biocides, fungicides, and other microbial agents can also be included in the aqueous liquid vehicle.
  • Example antimicrobial agents can include NUOSEPT ® (Ashland Inc. (USA)), VANCIDE ® (R.T. Vanderbilt Co. (USA)), ACTICIDE ® B20 and ACTICIDE ® M20 (Thor Chemicals (U.K.)), PROXEL ® GXL (Arch Chemicals, Inc.(USA)), BARDAC ® 2250, 2280, BARQUAT ® 50-65B, and CARBOQUAT ® 250-T, (Lonza Ltd. Corp. (Switzerland)), KORDEK ® MLX (The Dow Chemical Co.
  • the total amount of antimicrobial agents in the liquid vehicle can range from about 0.1 wt% to about 1 wt% with respect to the total wt% of the jettable fluid.
  • Viscosity modifiers and buffers may also be present.
  • a buffer solution(s) can include potassium hydroxide, 2-[4-(2-hydroxyethyl) piperazin-1-yl] ethane sulfonic acid, 2-amino-2-(hydroxymethyl)-1 ,3-propanediol (TRIZMA® sold by Sigma-Aldrich (USA)), 3-morpholinopropanesulfonic acid, triethanolamine, 2-[bis-(2-hydroxyethyl)-amino]-2-hydroxymethyl propane-1 ,3-diol (bis tris methane), N-methyl-D-glucamine, N,N,N’N’-tetrakis-(2-hydroxyethyl)- ethylenediamine and N,N,N’N’-tetrakis-(2-hydroxypropyl)-ethylenediamine, beta- alanine, betaine, or mixtures thereof.
  • potassium hydroxide 2-[4-(2-hydroxyethyl) piperazin-1-yl] ethane s
  • the buffer solution(s) can include 2-amino-2-(hydroxymethyl)-1 ,3-propanediol (TRIZMA® sold by Sigma-Aldrich (USA)), beta-alanine, betaine, or mixtures thereof.
  • Such additives can be present at from 0.01 wt% to 20 wt%.
  • aqueous liquid vehicle refers to water and in some examples, other components such as surfactants, solvents, co-solvents, anti-kogation agents, buffers, biocides, sequestering agents, viscosity modifiers, surface-active agents, and the like.
  • jetting or “jettable” refers to compositions that are ejectable from a jetting architecture, such as ink-jet architecture.
  • Ink-jet architecture can include thermal or piezo pens with printing orifices or openings suitable for ejection of small droplets of fluid.
  • the fluid droplet size can be less than 10 picoliters, less than 20 picoliters, less than 30 picoliters, less than 40 picoliters, less than 50 picoliters, etc.
  • the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint.
  • the degree of flexibility of this term can be dictated by the particular variable and determined based on experience and the associated description herein.
  • the various adhesion promoting agents were applied as four separate layers independently between five layers of polystyrene build material film.
  • the adhesion promoting agent formulations were screened based on the marks on the individual build material film layers.
  • Formulations 3 and 5 left permanent marks on individual film layers (due to the dye) upon wiping with ethanol and were used successfully in binding the build material film layers together.
  • Formulations 1 , 2, and 4 did not leave marks and were not tested for binding ability.

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
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  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)

Abstract

L'invention concerne un procédé d'impression en trois dimensions pouvant comprendre l'application itérative de couches individuelles de film de matériau de construction, les couches individuelles pouvant avoir indépendamment une épaisseur allant d'environ 5 µm à environ 1 cm. Le procédé peut également consister à faire adhérer de manière itérative des couches individuelles immédiatement adjacentes et empilées les unes aux autres pour devenir jointes. L'adhérence itérative peut comprendre l'application d'un agent favorisant l'adhérence pour joindre les couches individuelles immédiatement adjacentes et empilées, l'application de chaleur pour joindre les couches individuelles immédiatement adjacentes et empilées, ou les deux. Le procédé peut en outre comprendre, sur la base d'un modèle d'objet en trois dimensions, la découpe de manière itérative et sélective d'une seule couche ou d'une pluralité de couches du film de matériau de construction après leur jonction pour établir une partie d'une surface extérieure définissant un volume d'un objet en trois dimensions.
PCT/US2019/068120 2019-12-20 2019-12-20 Impression en trois dimensions avec des films de matériau de construction WO2021126271A1 (fr)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11802320B2 (en) 2020-12-28 2023-10-31 Alloy Enterprises, Inc. Homogenizing heterogeneous foils for light alloy metal parts
US12000009B2 (en) 2023-08-25 2024-06-04 Alloy Enterprises Inc. Homogenizing heterogeneous foils for light alloy metal parts

Citations (3)

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Publication number Priority date Publication date Assignee Title
UA26362C1 (uk) * 1994-01-26 1999-08-30 Амп-Акцо Ліhлем Воф Спосіб виготовлеhhя композитhої шаруватої коhструкції, підкладка для плати з печатhим моhтажем та багатошарова плата з печатhим моhтажем hа її осhові
US6506477B1 (en) * 1998-12-17 2003-01-14 Minolta Co., Ltd. Apparatus and method for forming three-dimensional object
WO2011094470A1 (fr) * 2010-01-29 2011-08-04 Monosol, Llc Film hydrosoluble amélioré comprenant un mélange de polymères pvoh, et paquets constitués à partir de celui-ci

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
UA26362C1 (uk) * 1994-01-26 1999-08-30 Амп-Акцо Ліhлем Воф Спосіб виготовлеhhя композитhої шаруватої коhструкції, підкладка для плати з печатhим моhтажем та багатошарова плата з печатhим моhтажем hа її осhові
US6506477B1 (en) * 1998-12-17 2003-01-14 Minolta Co., Ltd. Apparatus and method for forming three-dimensional object
WO2011094470A1 (fr) * 2010-01-29 2011-08-04 Monosol, Llc Film hydrosoluble amélioré comprenant un mélange de polymères pvoh, et paquets constitués à partir de celui-ci

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11802320B2 (en) 2020-12-28 2023-10-31 Alloy Enterprises, Inc. Homogenizing heterogeneous foils for light alloy metal parts
US11807912B2 (en) 2020-12-28 2023-11-07 Alloy Enterprises, Inc. Homogenizing heterogeneous foils for light alloy metal parts
US11859261B2 (en) 2020-12-28 2024-01-02 Alloy Enterprises, Inc. Homogenizing heterogeneous foils for light alloy metal parts
US11981974B2 (en) 2020-12-28 2024-05-14 Alloy Enterprises Inc. Homogenizing heterogeneous foils for light alloy metal parts
US11987858B2 (en) 2020-12-28 2024-05-21 Alloy Enterprises Inc. Homogenizing heterogeneous foils for light alloy metal parts
US12000009B2 (en) 2023-08-25 2024-06-04 Alloy Enterprises Inc. Homogenizing heterogeneous foils for light alloy metal parts
US12000010B2 (en) 2023-08-28 2024-06-04 Alloy Enterprises Inc. Homogenizing heterogeneous foils for light alloy metal parts

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