WO2023278212A1 - Solutions and methods for treating additive manufactured compositions - Google Patents
Solutions and methods for treating additive manufactured compositions Download PDFInfo
- Publication number
- WO2023278212A1 WO2023278212A1 PCT/US2022/034503 US2022034503W WO2023278212A1 WO 2023278212 A1 WO2023278212 A1 WO 2023278212A1 US 2022034503 W US2022034503 W US 2022034503W WO 2023278212 A1 WO2023278212 A1 WO 2023278212A1
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- WO
- WIPO (PCT)
- Prior art keywords
- finishing solution
- solution
- finishing
- glycol
- cleaned
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims description 54
- 239000000203 mixture Substances 0.000 title abstract description 15
- 239000000654 additive Substances 0.000 title description 28
- 230000000996 additive effect Effects 0.000 title description 26
- 238000004140 cleaning Methods 0.000 claims abstract description 92
- 239000000463 material Substances 0.000 claims abstract description 55
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims abstract description 27
- 239000004094 surface-active agent Substances 0.000 claims abstract description 25
- 150000002009 diols Chemical class 0.000 claims abstract description 22
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 17
- SVTBMSDMJJWYQN-UHFFFAOYSA-N 2-methylpentane-2,4-diol Chemical compound CC(O)CC(C)(C)O SVTBMSDMJJWYQN-UHFFFAOYSA-N 0.000 claims abstract description 14
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 claims abstract description 9
- 229940051250 hexylene glycol Drugs 0.000 claims abstract description 7
- 150000001298 alcohols Chemical group 0.000 claims abstract description 4
- 230000008569 process Effects 0.000 claims description 18
- 150000001875 compounds Chemical class 0.000 claims description 11
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 claims description 9
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 8
- PUPZLCDOIYMWBV-UHFFFAOYSA-N (+/-)-1,3-Butanediol Chemical compound CC(O)CCO PUPZLCDOIYMWBV-UHFFFAOYSA-N 0.000 claims description 6
- 239000003518 caustics Substances 0.000 claims description 4
- GSPKZYJPUDYKPI-UHFFFAOYSA-N diethoxy sulfate Chemical compound CCOOS(=O)(=O)OOCC GSPKZYJPUDYKPI-UHFFFAOYSA-N 0.000 claims description 4
- 229940043375 1,5-pentanediol Drugs 0.000 claims description 3
- 125000003158 alcohol group Chemical group 0.000 claims description 3
- 239000003599 detergent Substances 0.000 claims description 3
- WCVRQHFDJLLWFE-UHFFFAOYSA-N pentane-1,2-diol Chemical compound CCCC(O)CO WCVRQHFDJLLWFE-UHFFFAOYSA-N 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims 1
- 238000013019 agitation Methods 0.000 description 11
- 239000007788 liquid Substances 0.000 description 11
- 238000012360 testing method Methods 0.000 description 10
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- 229920005989 resin Polymers 0.000 description 8
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- 238000003756 stirring Methods 0.000 description 6
- 239000002033 PVDF binder Substances 0.000 description 4
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 4
- 238000000527 sonication Methods 0.000 description 4
- 238000010146 3D printing Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- -1 diol compound Chemical class 0.000 description 3
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- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- 238000002604 ultrasonography Methods 0.000 description 3
- 101100000858 Caenorhabditis elegans act-3 gene Proteins 0.000 description 2
- 101100161935 Caenorhabditis elegans act-4 gene Proteins 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- HEFNNWSXXWATRW-UHFFFAOYSA-N Ibuprofen Chemical compound CC(C)CC1=CC=C(C(C)C(O)=O)C=C1 HEFNNWSXXWATRW-UHFFFAOYSA-N 0.000 description 2
- 239000004809 Teflon Substances 0.000 description 2
- 229920006362 Teflon® Polymers 0.000 description 2
- 238000013036 cure process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000000110 selective laser sintering Methods 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 238000011179 visual inspection Methods 0.000 description 2
- JYCQQPHGFMYQCF-UHFFFAOYSA-N 4-tert-Octylphenol monoethoxylate Chemical compound CC(C)(C)CC(C)(C)C1=CC=C(OCCO)C=C1 JYCQQPHGFMYQCF-UHFFFAOYSA-N 0.000 description 1
- 102100031102 C-C motif chemokine 4 Human genes 0.000 description 1
- 101100054773 Caenorhabditis elegans act-2 gene Proteins 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
- 241000405961 Scomberomorus regalis Species 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000012459 cleaning agent Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method 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
- 230000008021 deposition Effects 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 239000003995 emulsifying agent Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000003020 moisturizing effect Effects 0.000 description 1
- 229920002113 octoxynol Polymers 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920001983 poloxamer Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000000244 polyoxyethylene sorbitan monooleate Substances 0.000 description 1
- 235000010482 polyoxyethylene sorbitan monooleate Nutrition 0.000 description 1
- 229920000053 polysorbate 80 Polymers 0.000 description 1
- 229940068968 polysorbate 80 Drugs 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 150000003138 primary alcohols Chemical class 0.000 description 1
- 239000000047 product Substances 0.000 description 1
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- 229930195735 unsaturated hydrocarbon Natural products 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
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- 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
- C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
- C11D3/16—Organic compounds
- C11D3/20—Organic compounds containing oxygen
- C11D3/2003—Alcohols; Phenols
- C11D3/2041—Dihydric alcohols
-
- C11D2111/14—
Definitions
- compositions and solutions for treating additive manufactured compositions or objects relate to compositions and solutions for reducing the brittleness of a surface of an additive manufactured object, e.g., following the removal of unwanted material such as uncured or cured support material from the surface of the object.
- the disclosure also relates to methods of using such compositions or solutions in treating the surface of the additive manufactured object to reduce a brittleness of the object.
- Additive manufacturing processes such as 3D printing (e.g., Selective Laser Sintering (SLS), Stereolithography (SLA), fused deposition modeling (FDM), material jetting (MJ) such as PolyJet, electron beam (e-beam), etc.) provide significant advantages for many applications.
- Additive manufacturing processes enable the production of parts having complex geometries that would be difficult to make using traditional manufacturing techniques.
- additive manufacturing processes enable the efficient production of low volumes of parts.
- some additive manufacturing processes produce parts that require removal of unwanted material, such as uncured or cured support material. The unwanted material is produced during the printing portion of the additive manufacturing process and may be needed to support portions of the part as the part is being printed. After the printing portion of the process is completed, the unwanted material must be removed before the part can be used for its intended purpose.
- the unwanted material itself may have a complex geometry and may 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 may be rough because edges of the layers may not align precisely with each other, thus creating a rough, bumpy outer surface. This outer surface may be unappealing visually or may have stress concentrations or irregularities, which need to be removed before testing or use.
- Some solutions for additive manufactured objects while valuable in cleaning and removing the unwanted material from the surface of the object, may increase the brittleness of the object. In some cases, this increase in brittleness may be undesirable for the end product's use. That is, the cleaned 3D printed object may become prone to breaking when a typical pressure in the object's lifecycle is applied to the object. As such, there remains a need for a finishing solution to treat and reduce the brittleness of an object, particularly following treatment of the additive manufactured object (e.g., in a post-cleaning finishing process).
- the disclosure provides compositions or finishing solutions and methods for treating a surface of an (e.g., additive manufactured) object.
- the disclosure further provides products formed from use of the finishing solution, wherein a brittleness measured on surface of the object has been reduced.
- a finishing solution configured to treat a surface of an object.
- the finishing solution includes a diol, a surfactant, and water.
- the finishing solution is configured to reduce a brittleness of the surface of the object following application of the finishing solution to the surface of the object.
- a method of treating a surface of an object includes providing a finishing solution having a diol, a surfactant, and water; submerging the object in the finishing solution; and removing the object from the finishing solution, wherein a brittleness of the surface of the object has been reduced.
- a cleaned and treated object is formed by a process of: submerging, in a cleaning solution, an object having the unwanted material on the surface of the object; agitating the object while the object is submerged in the cleaning solution; removing the object from the cleaning solution, wherein the unwanted material has been removed from the surface of the object and remains within the cleaning solution, therein forming a cleaned object; submerging the cleaned object in a finishing solution, wherein the finishing solution comprises a diol, a surfactant, and water, wherein the finishing solution reduces the brittleness of the surface of the cleaned object; and removing the cleaned object from the finishing solution, therein forming the cleaned and treated object.
- Figure 1 depicts a flow diagram of an exemplary method of using a finishing solution.
- Figure 2A depicts an example of a machine configured to be used to finish a 3D- printed object with a finishing solution.
- Figure 2B is a cross-sectional view of the machine depicted in Figure 2A.
- compositions and methods are representative of embodiments in various forms, specific embodiments are illustrated in the drawings (and are hereafter described), with the understanding that the disclosure is intended to be illustrative and is not intended to limit the claim scope to the specific embodiments described and illustrated herein.
- the disclosure may be embodied as one or more finishing compositions or solutions configured to treat the surface of additively manufactured polymers, resins, plastic materials, or parts, (e.g., a 3D printed object).
- the resin undergoes a curing process with the laser during the print process. In such a 3D printing process, some uncured or unwanted (e.g., support) material may remain on the surface of the printed object.
- the amount of uncured or unwanted material on the surface of the additively manufactured, (e.g., 3D printed), object may vary based on the type of printing process used or the type or structure of object being formed.
- the uncured or unwanted material may be removed from the surface of the object using a cleaning solution to provide a cleaned and, in some examples, at least partially cured, object.
- cleaning formulations include PLM-101-SUB and PLM-202-SUB, which are available from PostProcess Technologies, Inc., and the formulations disclosed in WO 2020/006141, which is incorporated by reference herein in its entirety, as well as other caustic-based solutions.
- a post-cure process of the object may be performed using a UV oven.
- the unwanted material 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 object is subjected to a finishing solution to treat the surface of the cleaned object, which may be become more brittle when exposed to certain compounds within the cleaning solution (e.g., caustic and/or detergent compounds).
- a finishing solution to treat the surface of the cleaned object, which may be become more brittle when exposed to certain compounds within the cleaning solution (e.g., caustic and/or detergent compounds).
- a finishing solution may be applied directly to an additive manufactured object (not subjected to a cleaning solution) to treat and improve the brittleness of the object.
- object may refer to an additive manufactured or 3D- printed object that is not in its desired final form.
- cleaning may refer to removing unwanted material from the surface of an additive manufactured object (e.g., a 3D-printed object). Cleaning may include one or more processes, including, but not limited to, removing uncured material, removing unwanted resin, removing unwanted metal powder, removing unwanted print material, and/or removing unwanted material.
- finishing may refer to treating the additive manufactured object to reduce the brittleness of the surface of the object, e.g., following the removal of unwanted material such as uncured material or resins from the surface of the object.
- unwanted material may include uncured material or unwanted support material (e.g., on a surface of a 3D printed object). Unwanted material may be the same material as the object being manufactured or may be a different material.
- the material that may be removed during cleaning include, but are not limited to Digital, Digital ABS, Helios, VeroClear, Cero, Rigur, Tango, and Med610 materials.
- the materials that may be removed during cleaning 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, WaterClear Ultra, Somos
- agitated may refer to effecting movement by an outside force.
- agitation include moving the cleaning or finishing solution via a pump, stirring, using longitudinal waves at an ultrasonic frequency, or combinations thereof.
- Improved compositions or finishing solutions for improving (i.e., reducing) the brittleness of the surface of an object may include a diol, a surfactant, water, and (optionally) one or more additional additive compounds.
- such a compound may be advantageous in coating or moisturizing an object, which in the present application is useful in improving (i.e., reducing) the brittleness of the additive manufactured object.
- such a diol compound may be helpful in reducing brittleness of an additive manufactured object that has been subjected to a cleaning with a caustic solution.
- the diol may be an aliphatic diol (i.e., a glycol).
- the aliphatic diol may include an unsaturated hydrocarbon having two hydroxyl groups.
- the aliphatic diol or glycol may include ethylene glycol, propylene glycol, butylene glycol, pentylene glycol, hexylene glycol, and so on.
- the diol includes hexylene glycol.
- the finishing solution may also include a surfactant compound.
- the surfactant compound may additionally be advantageous in improving (reducing) the brittleness of the surface of the additive manufactured object. Specifically, such a surfactant compound may be helpful in reducing brittleness of an additive manufactured object that has been subjected to a cleaning solution with organic detergent compounds.
- the surfactant is an alcohol ethoxylate or an alcohol ethoxysulfate.
- the alcohol present in the surfactant compound may be a linear primary alcohol.
- the alcohol ethoxylate or ethoxysulfate has a carbon chain length in a range of 8-18 carbon atoms.
- the surfactant includes C9-11 ethoxylated alcohols.
- the alcohol ethoxylate includes octyl phenol ethoxylate, polysorbate 80, and/or poloxamers.
- the finishing solution may also include water.
- water makes up the remaining compound of the finishing solution (ignoring any impurities present).
- an optional additive such as an additional cleaning agent, emulsifier, surfactant, etc. may be present to provide additional assistance in the treatment of the surface of the additive manufactured object. Finishing Solutions by Weight %
- the amount of diol present in the finishing solution may be in a range of 1-40 wt.%, 5-30 wt.%, 10-25 wt.%, 10-20 wt.%, or 15-25 wt.%.
- the amount of surfactant present in the finishing solution may be in a range of 1- 40 wt.%, 5-30 wt.%, 10-25 wt.%, 10-20 wt.%, or 15-25 wt.%.
- the amount of water present in the finishing solution may be in a range of 30-99 wt.%, 40-90 wt.%, 50-80 wt.%, or 60-70 wt.%.
- such a finishing solution may include: (a) 10-25% by weight of the diol, (b) 10-25% by weight of the surfactant; and (c) 50-80% by weight of water. Additional permutations are possible based on the exemplary weight percentages of the various components identified above, for example.
- the total weight percent of the diol, surfactant, and water add up to 100% (i.e., wherein the total weight percent of these components ignores any further additives or impurities present in the finishing solution).
- an additive manufactured object e.g., 3D-printed object
- a process to remove unwanted material e.g., 3D-printed object
- the cleaned object may then be subjected to a finishing solution to adjust or improve (i.e., reduce) the brittleness of the cleaned object.
- the object is placed in a tank that has been filled (e.g., filled at least partially) with a liquid cleaning solution.
- the object may be submerged in the cleaning solution.
- the object While the object is in the cleaning solution (e.g., submerged in the cleaning 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 cleaning 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 cleaning solution through one or more nozzles (e.g., spraying), which apply the cleaning solution to the object and mechanically agitates the object.
- the liquid may include chemical solvents to dissolve unwanted material, and thereby create a cleaned form of the object.
- Heat from a heat source may be used to maintain the cleaning solution at a desired temperature. Under these conditions, the unwanted material may be removed thermally, chemically, mechanically or via a combination of two or more of these methods.
- the 3D printed object is subjected to a finishing solution to treat the surface of the object to improve (i.e., reduce) the brittleness of the object.
- a finishing solution to treat the surface of the object to improve (i.e., reduce) the brittleness of the object.
- a similar process to the cleaning solution application may be used for the finishing solution and surface treatment of the object.
- the object may be submerged within the finishing solution and, in some examples, subjected to application of mechanical energy, such as agitation, in order to treat the surface of 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 instead of submerging the object in the finishing solution to treat the object, the object may be 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 (e.g., spraying), which apply the finishing solution to the object and mechanically agitates the object.
- Heat from a heat source may be used to maintain the finishing solution at a desired temperature. Under these conditions, the surface of the 3D printed object may be treated to improve/reduce the brittleness of the object.
- Figure 1 depicts a flow diagram of an exemplary method of such a process.
- the steps of such a method may be sufficient to treat the surface of 3D-printed object (e.g., which has been subjected to a cleaning solution to remove unwanted material from the surface of the object).
- the method as depicted in Figure 1 may include optional acts 1-3.
- a cleaning solution may be applied to an object or a portion thereof.
- Application of the cleaning solution may be accomplished by submerging in the cleaning solution all or part of the object that requires cleaning.
- 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 cleaning.
- the cleaning solution may 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.
- the cleaning solution may be heated to or maintained at a temperature to increase the rate of solubilization of unwanted resin.
- the cleaning solution may be kept at temperatures up to 55°C (131°F) (including all 0.1°C or 0.1°F values and ranges between 20°C (68°F) and 55°C (131°F)), before the object is submerged and/or while the object is submerged.
- 55°C 131°F
- appropriate handling precautions may be taken.
- the object may be soaked and/or agitated within the cleaning solution during at least part of the application.
- Agitation and/or vibration may be induced by methods such as, but are not limited to, sonication (e.g., via an ultrasonic transducer sending ultrasonic longitudinal waves into the cleaning 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 cleaning solution
- a pump e.g., using a pump to effect fluid movement
- stirring or a combination thereof.
- An example of such equipment is disclosed in Figures 2A and 2B, discussed in greater detail below.
- Stirring of the cleaning solution may be performed by the use of an impeller, mechanical stirrer, stir bar, or the like.
- the cleaning solution may be agitated for 0-60 minutes, including all 1 second values and ranges therebetween (e.g., 1-60 minutes, 10-30 minutes, 1-15 minutes, 15-30 minutes, 30-60 minutes, etc.), prior to the object being submerged and/or while the object is submerged.
- 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 cleaning solution may agitate the cleaning solution such that the cleaning solution does not separate into distinct phases and/or such that a force is applied to the object, or to move the cleaning solution. Applying a force to the object helps dislodge and/or dissolve unwanted material.
- Such a cleaning solution may be agitated for 0-60 minutes, including all 1 second values and ranges therebetween (e.g., 1-60 minutes, 10-30 minutes, 1-15 minutes, 15-30 minutes, 30-60 minutes, etc.), prior to the object being submerged, and/or while the object is submerged.
- 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.
- 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 material has been reached. As unwanted material is removed, the resonant frequency of the remaining material may change, and so the process of selecting an ultrasonic agitation frequency may need to be repeated from time to time.
- the object 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.
- the object may be removed from the cleaning solution to provide a (e.g., at least partially cured and) cleaned object. The cleaned object may be subsequently rinsed or dried.
- the cleaning solution may be recovered after the cleaning operations are concluded. Steps for recovering the cleaning solution may include allowing cleaning solution to drip from the object back into a tank containing the cleaning solution.
- the object may be rinsed with water or other suitable solvent. Such rinsing may be necessary to remove cleaning 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 may 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 cleaning.
- a finishing solution may be applied to the (cleaned) object.
- the finishing solution may be applied by submerging the object (or a portion of the object) into the finishing solution.
- a finishing solution may be sprayed onto the surface of the object to treat the brittleness of the surface.
- finishing solution may be accomplished by submerging in the finishing solution all or part of the object that requires finishing.
- the finishing solution may be stored in a holding vessel/container/tank.
- 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.
- the finishing solution may be stored in a similar or different holding vessel as the cleaning solution discussed above. In some examples, the same holding vessel as the cleaning solution may be used, wherein the cleaning solution is removed from the holding vessel following act 3 and the finishing solution is added prior to act 4.
- the object may be soaked and/or agitated within the finishing solution during at least part of the application.
- Agitation and/or vibration may be induced by methods such as, but are not limited to, sonication (e.g., via an ultrasonic transducer sending ultrasonic longitudinal waves into the cleaning 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 cleaning solution
- a pump e.g., using a pump to effect fluid movement
- stirring e.g., a combination thereof.
- An example of such equipment is disclosed in Figures 2A and 2B, discussed in greater detail below.
- the object may be soaked or maintained within the finishing solution for 0-180 minutes, including all 1 second values and ranges therebetween (e.g., 1-180 minutes, 1-60 minutes, 60-180 minutes, 10-30 minutes, 1-15 minutes, 15-30 minutes, 30-60 minutes, etc.).
- the finishing solution may be agitated (e.g., via sonication or stirring as described above) for none, a portion less than all, or all of the time the object is submerged.
- the object may be removed from the finishing solution to provide a treated object.
- the treated object may be subsequently rinsed or dried.
- Figure 2A depicts an example of a machine configured to be used for certain methods described herein with the cleaning and finishing solutions described herein to clean and treat a 3D-printed object.
- Figure 2B is a cross-sectional view of the machine depicted in Figure 2A as identified by the cross-section '2B'.
- Figures 2A and 2B depict a cleaning or finishing machine 100, a control panel 12, cover doors 10, a front panel 8, a tank 28 configured to hold a cleaning or finishing solution (as described herein), 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.
- the cleaning or finishing machine 100 may be used in a method to clean and/or treat a 3D-printed object by: (a) adding a cleaning solution into a tank (28) of a machine (e.g., a machine 100 used for cleaning a 3D printed object; (b) using a heater that is arranged in the tank 28 to heat the cleaning solution to a desired temperature; (c) using a pump to move the cleaning solution within the tank; (d) using an ultrasonic transducer 22 arranged relative to the tank to provide ultrasonic longitudinal waves and/or cavitation within the tank that agitate the cleaning solution; and (e) contacting an object with the cleaning solution for a desired time to remove unwanted material from the object.
- a machine e.g., a machine 100 used for cleaning a 3D printed object
- a heater that is arranged in the tank 28 to heat the cleaning solution to a desired temperature
- a pump to move the cleaning solution within the tank
- an ultrasonic transducer 22 arranged relative to the tank to provide ultra
- Additional agitation may reduce the amount of time needed to remove unwanted material or treat the surface of the object.
- Using such a machine may involve: (a) adding a cleaning or finishing solution 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 2A and Figure 2B) and pouring the cleaning or finishing solution directly into a tank 28; (b) mixing the cleaning or finishing solution (e.g., mixing may be performed by a pump and/or ultrasonic agitation) sufficiently so that the cleaning or finishing solution does not separate; (c) heating the cleaning or finishing solution via a submerged heater arranged in the tank, in order to heat the cleaning or finishing solution to a desired temperature; (d) pumping the cleaning or finishing solution using a pump that may be arranged below the tank, in order to move the cleaning or finishing solution through the tank and thereby agitate the solution and/or object.
- a cleaning or finishing solution into a machine 100 from the top of the machine by lifting
- the machine may be filled with cleaning or 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 cleaning or finishing solution may be premixed before being added to the reservoir. In addition, the cleaning or finishing solution may need to be mixed after the cleaning or finishing solution has been added to the tank 28 in order to prevent separation of the components
- the finishing solution described above is used to treat a surface of a 3D printed object that has undergone a cleaning with a cleaning solution to remove unwanted material from the surface of the 3D printed object.
- the surface of the cleaned object may have an undesired increase in the brittleness of the surface of the object.
- This brittleness of the cleaned object may be identified via visual inspection, hand testing, or a standardized test known to those in the art to identify/quantify a characteristic of the surface of the cleaned object.
- the standardized test is ASTM D638, a test method for tensile properties of plastics. Additionally, or alternatively, the standardized test used may be International Standard ISO 178, a determination of flexural properties of rigid and semi-rigid plastics.
- the cleaned object is soaked or treated with the finishing solution identified in the example above. Following the treatment, the brittleness of the object has been improved (i.e., reduced). This improvement of the brittleness on the surface of the treated object may be identified via visual inspection, hand testing, or a standardized test known to those in the art to identify/quantify a characteristic of the surface of the cleaned object (e.g., ASTM D638 and/or ISO 178). Additional, or alternative, standardized tests may also be employed. [0069] The testing results of the cleaned object and the treated object may be compared with each other to identify the improvement in the surface properties of the object (e.g., the percentage decrease in brittleness of the treated object versus the cleaned object).
- inventions of the disclosure may be referred to herein, individually and/or collectively, by the term "invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept.
- inventions merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept.
- specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown.
- This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, are apparent to those of skill in the art upon reviewing the description.
- the singular forms "a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
Abstract
The disclosure relates to compositions or finishing solutions configured to treat the surface of and reduce the brittleness of the surface of an additively manufactured object (e.g., following a cleaning of the object to remove unwanted material from the surface of the object). In one example, the finishing solution includes a diol, a surfactant, and water. In certain examples, the diol is a glycol such as hexylene glycol and the surfactant is an ethoxylated alcohol.
Description
SOLUTIONS AND METHODS FOR TREATING ADDITIVE MANUFACTURED COMPOSITIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/217,905, filed July 2, 2021, which is hereby incorporated by reference in its entirety.
FIELD
[0002] The following disclosure relates to compositions and solutions for treating additive manufactured compositions or objects. In particular, the disclosure relates to compositions and solutions for reducing the brittleness of a surface of an additive manufactured object, e.g., following the removal of unwanted material such as uncured or cured support material from the surface of the object. The disclosure also relates to methods of using such compositions or solutions in treating the surface of the additive manufactured object to reduce a brittleness of the object.
BACKGROUND
[0003] Additive manufacturing processes, such as 3D printing (e.g., Selective Laser Sintering (SLS), Stereolithography (SLA), fused deposition modeling (FDM), material jetting (MJ) such as PolyJet, electron beam (e-beam), etc.) provide significant advantages for many applications. Additive manufacturing processes enable the production of parts having complex geometries that would be difficult to make using traditional manufacturing techniques. Also, additive manufacturing processes enable the efficient production of low volumes of parts. However, some additive manufacturing processes produce parts that require removal of unwanted material, such as uncured or cured support material. The unwanted material is produced during the printing portion of the additive manufacturing process and may be needed to support portions of the part as the part is being printed. After the printing portion of the process is completed, the unwanted material must be removed before the part can be used for its intended purpose.
[0004] The unwanted material itself may have a complex geometry and may 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 may be rough because edges of the layers may not align precisely with each other, thus creating a rough, bumpy outer surface. This outer surface may be unappealing visually or
may have stress concentrations or irregularities, which need to be removed before testing or use.
[0005] Some solutions for additive manufactured objects, while valuable in cleaning and removing the unwanted material from the surface of the object, may increase the brittleness of the object. In some cases, this increase in brittleness may be undesirable for the end product's use. That is, the cleaned 3D printed object may become prone to breaking when a typical pressure in the object's lifecycle is applied to the object. As such, there remains a need for a finishing solution to treat and reduce the brittleness of an object, particularly following treatment of the additive manufactured object (e.g., in a post-cleaning finishing process).
SUMMARY
[0006] The disclosure provides compositions or finishing solutions and methods for treating a surface of an (e.g., additive manufactured) object. The disclosure further provides products formed from use of the finishing solution, wherein a brittleness measured on surface of the object has been reduced.
[0007] In one embodiment, a finishing solution configured to treat a surface of an object is provided. The finishing solution includes a diol, a surfactant, and water. The finishing solution is configured to reduce a brittleness of the surface of the object following application of the finishing solution to the surface of the object.
[0008] In another embodiment, a method of treating a surface of an object is disclosed. The method includes providing a finishing solution having a diol, a surfactant, and water; submerging the object in the finishing solution; and removing the object from the finishing solution, wherein a brittleness of the surface of the object has been reduced.
[0009] In another embodiment, a cleaned and treated object is formed by a process of: submerging, in a cleaning solution, an object having the unwanted material on the surface of the object; agitating the object while the object is submerged in the cleaning solution; removing the object from the cleaning solution, wherein the unwanted material has been removed from the surface of the object and remains within the cleaning solution, therein forming a cleaned object; submerging the cleaned object in a finishing solution, wherein the finishing solution comprises a diol, a surfactant, and water, wherein the finishing solution
reduces the brittleness of the surface of the cleaned object; and removing the cleaned object from the finishing solution, therein forming the cleaned and treated object.
[0010] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Exemplary embodiments are described herein with reference to the following drawings.
[0012] Figure 1 depicts a flow diagram of an exemplary method of using a finishing solution.
[0013] Figure 2A depicts an example of a machine configured to be used to finish a 3D- printed object with a finishing solution.
[0014] Figure 2B is a cross-sectional view of the machine depicted in Figure 2A.
[0015] While the disclosed compositions and methods are representative of embodiments in various forms, specific embodiments are illustrated in the drawings (and are hereafter described), with the understanding that the disclosure is intended to be illustrative and is not intended to limit the claim scope to the specific embodiments described and illustrated herein.
DETAILED DESCRIPTION
[0016] Improved compositions or finishing solutions and their methods of making and use are disclosed herein.
[0017] Although the disclosure 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 disclosure. [0018] The disclosure may be embodied as one or more finishing compositions or solutions configured to treat the surface of additively manufactured polymers, resins, plastic materials, or parts, (e.g., a 3D printed object).
[0019] In certain examples, the resin undergoes a curing process with the laser during the print process. In such a 3D printing process, some uncured or unwanted (e.g., support) material may remain on the surface of the printed object. The amount of uncured or unwanted material on the surface of the additively manufactured, (e.g., 3D printed), object may vary based on the type of printing process used or the type or structure of object being formed. In certain examples, the uncured or unwanted material may be removed from the surface of the object using a cleaning solution to provide a cleaned and, in some examples, at least partially cured, object. Examples of such cleaning formulations include PLM-101-SUB and PLM-202-SUB, which are available from PostProcess Technologies, Inc., and the formulations disclosed in WO 2020/006141, which is incorporated by reference herein in its entirety, as well as other caustic-based solutions.
[0020] Following removal of unwanted material (e.g., uncured or unwanted support material) from the surface of the object, a post-cure process of the object may be performed using a UV oven. In other words, the unwanted material may be dissolved by a finishing solution of an embodiment before the object is placed into an ultraviolet ("UV") curing chamber for final curing. This removal of unwanted or uncured material prior to a final curing is advantageous, as such removal allows for the printed object to cure normally (e.g., in an expected or set amount of time).
[0021] Additionally, or alternatively to the post-cure process of the cleaned object, the object is subjected to a finishing solution to treat the surface of the cleaned object, which may be become more brittle when exposed to certain compounds within the cleaning solution (e.g., caustic and/or detergent compounds).
[0022] Alternatively, a finishing solution may be applied directly to an additive manufactured object (not subjected to a cleaning solution) to treat and improve the brittleness of the object.
Definitions
[0023] As used herein, the term "object" may refer to an additive manufactured or 3D- printed object that is not in its desired final form.
[0024] As used herein, the term "cleaning" may refer to removing unwanted material from the surface of an additive manufactured object (e.g., a 3D-printed object). Cleaning may include one or more processes, including, but not limited to, removing uncured material, removing unwanted resin, removing unwanted metal powder, removing unwanted print material, and/or removing unwanted material.
[0025] As used herein, the term "finishing" may refer to treating the additive manufactured object to reduce the brittleness of the surface of the object, e.g., following the removal of unwanted material such as uncured material or resins from the surface of the object.
[0026] As used herein, the term "unwanted material" may include uncured material or unwanted support material (e.g., on a surface of a 3D printed object). Unwanted material may be the same material as the object being manufactured or may be a different material. In certain examples, wherein the 3D printing is via material jetting such as PolyJet, the material that may be removed during cleaning include, but are not limited to Digital, Digital ABS, Helios, VeroClear, Cero, Rigur, Tango, and Med610 materials.
[0027] In alternative embodiments, the materials that may be removed during cleaning 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, WaterClear Ultra, Somos NeXt, and the like.
[0028] As used herein, the term "agitated" may refer to effecting movement by an outside force. With regard to the cleaning or finishing solution, non-limiting examples of
agitation include moving the cleaning or finishing solution via a pump, stirring, using longitudinal waves at an ultrasonic frequency, or combinations thereof.
Compositions or Finishing Solutions
[0029] Improved compositions or finishing solutions for improving (i.e., reducing) the brittleness of the surface of an object may include a diol, a surfactant, water, and (optionally) one or more additional additive compounds.
Diols
[0030] With regard to the diol, such a compound may be advantageous in coating or moisturizing an object, which in the present application is useful in improving (i.e., reducing) the brittleness of the additive manufactured object. Specifically, such a diol compound may be helpful in reducing brittleness of an additive manufactured object that has been subjected to a cleaning with a caustic solution.
[0031] In certain examples, the diol may be an aliphatic diol (i.e., a glycol). For instance, the aliphatic diol may include an unsaturated hydrocarbon having two hydroxyl groups. For instance, the aliphatic diol or glycol may include ethylene glycol, propylene glycol, butylene glycol, pentylene glycol, hexylene glycol, and so on. In one example, the diol includes hexylene glycol.
Surfactants
[0032] In addition to the diol, the finishing solution may also include a surfactant compound. The surfactant compound may additionally be advantageous in improving (reducing) the brittleness of the surface of the additive manufactured object. Specifically, such a surfactant compound may be helpful in reducing brittleness of an additive manufactured object that has been subjected to a cleaning solution with organic detergent compounds.
[0033] In certain examples, the surfactant is an alcohol ethoxylate or an alcohol ethoxysulfate. The alcohol present in the surfactant compound may be a linear primary alcohol. In certain examples, the alcohol ethoxylate or ethoxysulfate has a carbon chain
length in a range of 8-18 carbon atoms. In certain examples, the surfactant includes C9-11 ethoxylated alcohols.
[0034] In alternative examples, the alcohol ethoxylate includes octyl phenol ethoxylate, polysorbate 80, and/or poloxamers.
Water and additional optional additives
[0035] In addition to the diols and surfactants, the finishing solution may also include water. In certain examples, water makes up the remaining compound of the finishing solution (ignoring any impurities present). In alternative examples, an optional additive, such as an additional cleaning agent, emulsifier, surfactant, etc. may be present to provide additional assistance in the treatment of the surface of the additive manufactured object. Finishing Solutions by Weight %
[0036] The amount of diol present in the finishing solution may be in a range of 1-40 wt.%, 5-30 wt.%, 10-25 wt.%, 10-20 wt.%, or 15-25 wt.%.
[0037] The amount of surfactant present in the finishing solution may be in a range of 1- 40 wt.%, 5-30 wt.%, 10-25 wt.%, 10-20 wt.%, or 15-25 wt.%.
[0038] The amount of water present in the finishing solution may be in a range of 30-99 wt.%, 40-90 wt.%, 50-80 wt.%, or 60-70 wt.%.
[0039] In one particular example, such a finishing solution may include: (a) 10-25% by weight of the diol, (b) 10-25% by weight of the surfactant; and (c) 50-80% by weight of water. Additional permutations are possible based on the exemplary weight percentages of the various components identified above, for example.
[0040] In each of these examples, the total weight percent of the diol, surfactant, and water add up to 100% (i.e., wherein the total weight percent of these components ignores any further additives or impurities present in the finishing solution).
Methods of Use
[0041] In certain methods of use of the finishing solutions disclosed herein, an additive manufactured object (e.g., 3D-printed object) may be subjected to a process to remove unwanted material, and thereby provide a cleaned object. Following this removal/cleaning
process, the cleaned object may then be subjected to a finishing solution to adjust or improve (i.e., reduce) the brittleness of the cleaned object.
[0042] In one such method, the object is placed in a tank that has been filled (e.g., filled at least partially) with a liquid cleaning solution. The object may be submerged in the cleaning solution.
[0043] While the object is in the cleaning solution (e.g., submerged in the cleaning 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 cleaning 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 cleaning solution through one or more nozzles (e.g., spraying), which apply the cleaning solution to the object and mechanically agitates the object. In submersion and spraying processes, the liquid may include chemical solvents to dissolve unwanted material, and thereby create a cleaned form of the object. Heat from a heat source may be used to maintain the cleaning solution at a desired temperature. Under these conditions, the unwanted material may be removed thermally, chemically, mechanically or via a combination of two or more of these methods.
[0044] Following subjecting the object to the cleaning solution, or alternatively, instead of subjecting the object to the cleaning solution, the 3D printed object is subjected to a finishing solution to treat the surface of the object to improve (i.e., reduce) the brittleness of the object. A similar process to the cleaning solution application may be used for the finishing solution and surface treatment of the object.
[0045] In other words, the object may be submerged within the finishing solution and, in some examples, subjected to application of mechanical energy, such as agitation, in order to treat the surface of the object. Mechanical energy agitation may occur by moving the liquid finishing solution (e.g., via a pump) and/or by using ultrasound. Alternatively, instead of submerging the object in the finishing solution to treat the object, the object may be subjected to a liquid spray. In this process, the object is placed in a chamber, and a pump is used to force the liquid finishing solution through one or more nozzles (e.g., spraying),
which apply the finishing solution to the object and mechanically agitates the object. Heat from a heat source may be used to maintain the finishing solution at a desired temperature. Under these conditions, the surface of the 3D printed object may be treated to improve/reduce the brittleness of the object.
[0046] Figure 1 depicts a flow diagram of an exemplary method of such a process. The steps of such a method may be sufficient to treat the surface of 3D-printed object (e.g., which has been subjected to a cleaning solution to remove unwanted material from the surface of the object).
[0047] The method as depicted in Figure 1 may include optional acts 1-3. In optional act 1, a cleaning solution may be applied to an object or a portion thereof. Application of the cleaning solution may be accomplished by submerging in the cleaning solution all or part of the object that requires cleaning. 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 cleaning. The cleaning solution may 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.
[0048] The cleaning solution may be heated to or maintained at a temperature to increase the rate of solubilization of unwanted resin. For example, the cleaning solution may be kept at temperatures up to 55°C (131°F) (including all 0.1°C or 0.1°F values and ranges between 20°C (68°F) and 55°C (131°F)), before the object is submerged and/or while the object is submerged. At higher temperatures, e.g., higher than 55°C (131°F), appropriate handling precautions may be taken.
[0049] In optional act 2, the object may be soaked and/or agitated within the cleaning solution during at least part of the application. Agitation and/or vibration may be induced by methods such as, but are not limited to, sonication (e.g., via an ultrasonic transducer sending ultrasonic longitudinal waves into the cleaning solution), a pump (e.g., using a pump to effect fluid movement), stirring, or a combination thereof. An example of such equipment is disclosed in Figures 2A and 2B, discussed in greater detail below.
[0050] Stirring of the cleaning solution may be performed by the use of an impeller, mechanical stirrer, stir bar, or the like. The cleaning solution may be agitated for 0-60 minutes, including all 1 second values and ranges therebetween (e.g., 1-60 minutes, 10-30 minutes, 1-15 minutes, 15-30 minutes, 30-60 minutes, etc.), prior to the object being submerged and/or while the object is submerged.
[0051] 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 cleaning solution may agitate the cleaning solution such that the cleaning solution does not separate into distinct phases and/or such that a force is applied to the object, or to move the cleaning solution. Applying a force to the object helps dislodge and/or dissolve unwanted material. Such a cleaning solution may be agitated for 0-60 minutes, including all 1 second values and ranges therebetween (e.g., 1-60 minutes, 10-30 minutes, 1-15 minutes, 15-30 minutes, 30-60 minutes, etc.), prior to the object being submerged, and/or while the object is submerged. [0052] 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.
[0053] This process may be repeated until the detected amplitude indicates (e.g., indicates through sensor feedback) that a resonant frequency of unwanted material has been reached. As unwanted material is removed, the resonant frequency of the remaining material 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.
[0054] In optional act 3, the object may be removed from the cleaning solution to provide a (e.g., at least partially cured and) cleaned object. The cleaned object may be subsequently rinsed or dried. Further, the cleaning solution may be recovered after the cleaning operations are concluded. Steps for recovering the cleaning solution may include allowing cleaning solution to drip from the object back into a tank containing the cleaning solution. The object may be rinsed with water or other suitable solvent. Such rinsing may be necessary to remove cleaning solution that remains on the object. Following application of the cleaning 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 may 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 cleaning.
[0055] In act 4, a finishing solution may be applied to the (cleaned) object. The finishing solution may be applied by submerging the object (or a portion of the object) into the finishing solution. Alternatively, a finishing solution may be sprayed onto the surface of the object to treat the brittleness of the surface.
[0056] Application of the finishing solution may be accomplished by submerging in the finishing solution all or part of the object that requires finishing. The finishing solution may 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. The finishing solution may be stored in a similar or different holding vessel as the cleaning solution discussed above. In some examples, the same holding vessel as the cleaning solution may be used, wherein the cleaning solution is removed from the holding vessel following act 3 and the finishing solution is added prior to act 4.
[0057] In act 5, the object may be soaked and/or agitated within the finishing solution during at least part of the application. Agitation and/or vibration may be induced by
methods such as, but are not limited to, sonication (e.g., via an ultrasonic transducer sending ultrasonic longitudinal waves into the cleaning solution), a pump (e.g., using a pump to effect fluid movement), stirring, or a combination thereof. An example of such equipment is disclosed in Figures 2A and 2B, discussed in greater detail below.
[0058] The object may be soaked or maintained within the finishing solution for 0-180 minutes, including all 1 second values and ranges therebetween (e.g., 1-180 minutes, 1-60 minutes, 60-180 minutes, 10-30 minutes, 1-15 minutes, 15-30 minutes, 30-60 minutes, etc.). The finishing solution may be agitated (e.g., via sonication or stirring as described above) for none, a portion less than all, or all of the time the object is submerged.
[0059] In act 6, the object may be removed from the finishing solution to provide a treated object. The treated object may be subsequently rinsed or dried.
[0060] Figure 2A depicts an example of a machine configured to be used for certain methods described herein with the cleaning and finishing solutions described herein to clean and treat a 3D-printed object. Figure 2B is a cross-sectional view of the machine depicted in Figure 2A as identified by the cross-section '2B'.
[0061] Figures 2A and 2B depict a cleaning or finishing machine 100, a control panel 12, cover doors 10, a front panel 8, a tank 28 configured to hold a cleaning or finishing solution (as described herein), 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.
[0062] The cleaning or finishing machine 100 may be used in a method to clean and/or treat a 3D-printed object by: (a) adding a cleaning solution into a tank (28) of a machine (e.g., a machine 100 used for cleaning a 3D printed object; (b) using a heater that is arranged in the tank 28 to heat the cleaning solution to a desired temperature; (c) using a pump to move the cleaning solution within the tank; (d) using an ultrasonic transducer 22 arranged relative to the tank to provide ultrasonic longitudinal waves and/or cavitation within the tank that agitate the cleaning solution; and (e) contacting an object with the cleaning solution for a desired time to remove unwanted material from the object.
[0063] Additional agitation, such as from a pump, may reduce the amount of time needed to remove unwanted material or treat the surface of the object. Using such a machine may involve: (a) adding a cleaning or finishing solution 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 2A and Figure 2B) and pouring the cleaning or finishing solution directly into a tank 28; (b) mixing the cleaning or finishing solution (e.g., mixing may be performed by a pump and/or ultrasonic agitation) sufficiently so that the cleaning or finishing solution does not separate; (c) heating the cleaning or finishing solution via a submerged heater arranged in the tank, in order to heat the cleaning or finishing solution to a desired temperature; (d) pumping the cleaning or finishing solution using a pump that may be arranged below the tank, in order to move the cleaning or finishing solution through the tank and thereby agitate the solution and/or object.
[0064] The machine may be filled with cleaning or 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 cleaning or finishing solution may be premixed before being added to the reservoir. In addition, the cleaning or finishing solution may need to be mixed after the cleaning or finishing solution has been added to the tank 28 in order to prevent separation of the components
EXAMPLES
[0066] In an example, the finishing solution described above is used to treat a surface of a 3D printed object that has undergone a cleaning with a cleaning solution to remove unwanted material from the surface of the 3D printed object.
[0067] Following the cleaning and removal of the unwanted material, the surface of the cleaned object may have an undesired increase in the brittleness of the surface of the object. This brittleness of the cleaned object may be identified via visual inspection, hand testing, or a standardized test known to those in the art to identify/quantify a characteristic of the surface of the cleaned object. In certain examples, the standardized test is ASTM D638, a test method for tensile properties of plastics. Additionally, or alternatively, the standardized test used may be International Standard ISO 178, a determination of flexural properties of rigid and semi-rigid plastics.
[0068] After identification/testing of physical properties of the cleaned object, the cleaned object is soaked or treated with the finishing solution identified in the example above. Following the treatment, the brittleness of the object has been improved (i.e., reduced). This improvement of the brittleness on the surface of the treated object may be identified via visual inspection, hand testing, or a standardized test known to those in the art to identify/quantify a characteristic of the surface of the cleaned object (e.g., ASTM D638 and/or ISO 178). Additional, or alternative, standardized tests may also be employed. [0069] The testing results of the cleaned object and the treated object may be compared with each other to identify the improvement in the surface properties of the object (e.g., the percentage decrease in brittleness of the treated object versus the cleaned object).
[0070] One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term "invention" merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, are apparent to those of skill in the art upon reviewing the description.
[0071] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.
[0072] As used herein, "for example," "for instance," "such as," or "including" are meant to introduce examples that further clarify more general subject matter. Unless otherwise expressly indicated, such examples are provided only as an aid for understanding embodiments illustrated in the present disclosure and are not meant to be limiting in any fashion. Nor do these phrases indicate any kind of preference for the disclosed embodiment.
[0073] The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.
[0074] It is intended that the foregoing detailed description be regarded as illustrative ratherthan limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the disclosure. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the disclosure.
Claims
1. A finishing solution configured to treat a surface of an object, the finishing solution comprising: a diol; a surfactant; and water, wherein the finishing solution is configured to reduce a brittleness of the surface of the object following application of the finishing solution to the surface of the object.
2. The finishing solution of claim 1, wherein the finishing solution has:
10-25% by weight of the diol;
10-25% by weight of the surfactant; and 50-80% by weight of the water.
3. The finishing solution of claim 1, wherein the diol is a glycol.
4. The finishing solution of claim 3, wherein the glycol is selected from the group consisting of ethylene glycol, propylene glycol, butylene glycol, pentylene glycol, hexylene glycol, and combinations thereof.
5. The finishing solution of claim 3, wherein the glycol is hexylene glycol.
6. The finishing solution of claim 1, wherein the surfactant is an alcohol ethoxylate or alcohol ethoxysulfate.
7. The finishing solution of claim 6, wherein the alcohol ethoxylate comprises C9- Cll ethoxylated alcohols.
8. The finishing solution of claim 1, wherein the object is a three-dimensional (3D) printed object.
9. The finishing solution of claim 8, wherein the 3D printed object has been cleaned with caustic and/or detergent compounds to at least partially remove unwanted support material from the surface of the 3D printed object.
10. A method of treating a surface of an object, the method comprising: providing a finishing solution having a diol, a surfactant, and water; submerging the object in the finishing solution; and removing the object from the finishing solution, wherein a brittleness of the surface of the object has been reduced.
11. The method of claim 10, further comprising: rinsing and/or drying the object following the removing of the object from the finishing solution.
12. The method of claim 10, further comprising: agitating the object while the object is submerged in the finishing solution.
13. The method of claim 10, wherein the object is a three-dimensional (3D) printed object.
14. The method of claim 13, further comprising, prior to the submerging of the object in the finishing solution: submerging the object in a cleaning solution to remove unwanted support material from the surface of the object.
15. The method of claim 10, wherein the object is submerged in the finishing solution for 1-60 minutes.
16. The method of claim 10, wherein the finishing solution comprises:
10-25% by weight of the diol;
10-25% by weight of the surfactant; and 50-80% by weight of the water.
17. The method of claim 16, wherein the diol is a glycol.
18. The method of claim 17, wherein the glycol is selected from the group consisting of ethylene glycol, propylene glycol, butylene glycol, pentylene glycol, hexylene glycol, and combinations thereof.
19. The method of claim 17, wherein the glycol is hexylene glycol.
20. The method of claim 16, wherein the surfactant is an alcohol ethoxylate or alcohol ethoxysulfate.
21. The method of claim 20, wherein the alcohol ethoxylate comprises C9-C11 ethoxylated alcohols.
22. A cleaned and treated object with unwanted support material removed from a surface of the cleaned and treated object and a brittleness of the surface of the cleaned and treated object reduced, wherein the cleaned and treated object is formed by a process of: submerging, in a cleaning solution, an object having the unwanted support material on the surface of the object; agitating the object while the object is submerged in the cleaning solution; removing the object from the cleaning solution, wherein the unwanted support material has been removed from the surface of the object and remains within the cleaning solution, therein forming a cleaned object;
submerging the cleaned object in a finishing solution, wherein the finishing solution comprises a diol, a surfactant, and water, wherein the finishing solution reduces the brittleness of the surface of the cleaned object; and removing the cleaned object from the finishing solution, therein forming the cleaned and treated object.
23. The cleaned and treated object of claim 22, wherein the object is a three- dimensional (3D) printed object.
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US63/217,905 | 2021-07-02 |
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