Method of using FDM to obtain specularly reflective surfaces

Patent metadata

Field	Value
Publication number	US-10589461-B2
Application number	US-201716331566-A
Country	US
Kind code	B2
Filing date	Sep 12, 2017
Priority date	Sep 22, 2016
Publication date	Mar 17, 2020
Grant date	Mar 17, 2020

Abstract

A method for 3D printing a 3D item ( 10 ), the method comprising providing a filament ( 320 ) of 3D printable material ( 201 ) and printing during a printing stage said 3D printable material ( 201 ) on a substrate ( 1550 ), to provide said 3D item ( 10 ), wherein the printing stage comprises (a) providing a layer ( 405 ) comprising particles ( 410 ) on the substrate ( 1550 ), wherein the particles ( 410 ) have a main axis (A 1 ) having a main axis length (LI), and a minor axis (A 2 ) having a minor axis length (L 2 ), wherein the main axis length (LI) and the minor axis length (L 2 ) have a first aspect ratio of at least 5, wherein in average the main axes (A 1 ) of said particles ( 410 ) are configured parallel to a tangential plane (P) to the substrate ( 1550 ), wherein said particles ( 410 ) comprise light reflective material ( 411 ), and (b) printing said 3D printable material ( 201 ) on said layer ( 405 ) on the substrate ( 1550 ) to provide said 3D item ( 10 ) comprising said layer ( 405 ).

First claim

The invention claimed is:

1. A method for 3D printing a 3D item, the method comprising providing a filament of 3D printable material and printing during a printing stage said 3D printable material on a substrate, to provide said 3D item, wherein the printing stage comprises:
(a) providing a layer comprising particles on the substrate, and
(b) printing said 3D printable material on said layer on the substrate to provide said 3D item comprising said layer,
wherein each particle has a main axis (A 1 ), a minor axis (A 2 ) and a further axis (A 3 ), the main axis (A 1 ), the minor axis (A 2 ), and the further axis (A 3 ) defining a rectangular parallelepiped with a smallest volume that encloses the particle,
wherein the main axis (A 1 ) has a main axis length (L 1 ), the minor axis (A 2 ) has a minor axis length (L 2 ), and the further axis (A 3 ) has a further axis length (L 3 ),
wherein the main axis length (L 1 ) and the minor axis length (L 2 ) have a first aspect ratio of at least 5,
wherein the further axis length (L 3 ) and the minor axis length (L 2 ) have a second aspect ratio of at least 5, and
wherein said particles comprise light reflective material.

2. The method according to claim 1 , wherein the particles have a first aspect ratio of at least 10, and wherein the layer has a layer thickness (d 1 ) selected from the range of 5 nm-200 μm.

3. The method according to claim 1 , wherein the particles have main axis lengths (L 1 ) selected from the range of 1-500 μm and minor axis lengths (L 2 ) selected from the range of 5 nm-10 μm, and wherein at least 80% of a surface area of the layer has a root mean square surface roughness of at maximum 25 nm.

4. The method according to claim 1 , wherein the main axes (A 1 ) of said particles have an angle (α) to a tangential plane (P) to the substrate selected from the range of 0-30°.

5. The method according to claim 1 , wherein the particles comprise one or more of metal particles and inorganic and organic particles, and wherein the particles comprise a light reflective coating.

6. The method according to claim 1 , wherein the substrate has the shape of a reflector with one or more of a curved face, a facetted face, and faces configured relative to each under an angle.

7. A 3D printed item comprising 3D printed material and a specular reflective layer on at least part of said 3D printed material, wherein the 3D printed material comprises a thermoplastic material, wherein the specular reflective layer comprises particles, wherein each particles has a main axis (A 1 ), a minor axis (A 2 ) and a further axis (A 3 ), the main axis (A 1 ), the minor axis (A 2 ), and the further axis (A 3 ) defining a rectangular parallelepiped with a smallest volume that encloses the particle, wherein the main axis (A 1 ) has a main axis length (L 1 ), the minor axis (A 2 ) has a minor axis length (L 2 ), and the further axis (A 3 ) has a further axis length (L 3 ), wherein the main axis length (L 1 ) and the minor axis length (L 2 ) have a first aspect ratio larger of at least 5, wherein the further axis length (L 3 ) and the minor axis length (L 2 ) have a second aspect ratio of at least 5, and wherein said particles comprise light reflective material.

8. The 3D printed item according to claim 7 , wherein the particles have a first aspect ratio of at least 10, wherein the layer has a layer thickness (d 1 ) selected from the range of 5 nm-2 mm, wherein the particles have main axis lengths (L 1 ) selected from the range of 1-500 μm and minor axis lengths (L 2 ) selected from the range of 5 nm-1 μm, and wherein at least 80% of a surface area of the layer has a root mean square surface roughness of at maximum 25 nm.

9. The 3D printed item according to claim 7 , wherein the main axes (A 1 ) of said particles have an angle (α) to a tangential plane (P) to the substrate selected from the range of 0-30°, and wherein the particles comprise one or more of metal particles and white particles.

10. A reflector ( 1 ) comprising a specular reflective surface ( 2 ), wherein the reflector ( 1 ) comprises the 3D printed item ( 10 ) according to claim 7 , and wherein at least part of the reflective surface ( 2 ) is provided by said specular reflective layer.

11. The reflector ( 1 ) according to claim 10 , wherein the reflective surface ( 2 ) comprises one or more of a curved face, a facetted face, and faces configured relative to each under an angle.

12. The reflector ( 1 ) according to claim 10 , wherein the reflector ( 1 ) is a collimator or a parabolic mirror.

13. A lighting system comprising (a) a light source configured to generate light source light and (b) a reflector ( 1 ) according to claim 10 configured to reflect at least part of said light source light.

Assignees

• Signify Holding Bv

Inventors

• Hikmet Rifat Ata Mustafa
• Van Bommel Ties

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29L2011/0083

  Reflectors · CPC title

• B29L2031/722

  Decorative or ornamental articles · CPC title

• B33Y80/00 Primary

  Products made by additive manufacturing · CPC title

• B29C70/585

  incorporation of light reflecting filler, e.g. lamellae to obtain pearlescent effet (partially embedding reflective elements into the surface of or support B29D11/00615) · CPC title