Methods for solid freeform fabrication

Patent metadata

Field	Value
Publication number	US-10688770-B2
Application number	US-201514637062-A
Country	US
Kind code	B2
Filing date	Mar 3, 2015
Priority date	Mar 3, 2015
Publication date	Jun 23, 2020
Grant date	Jun 23, 2020

Abstract

The present invention provides methods, processes, and systems for the manufacture of three-dimensional articles of polymer materials using 3D printing. A syringe or an inkjet print head prints a solution of prepolymer onto a build plate. The printed prepolymer is exposed to a stimulus whereby the prepolymer is converted to the polymer. After a predetermined time, sequential layers are printed to provide the three-dimensional article. The three-dimensional article can be cured to produce the 3D article made from the final polymer.

First claim

We claim:

1. A system for printing a three-dimensional article, the system comprising:
a solution of a prepolymer, wherein the prepolymer is a polysulfide, ketalized version of a polyketone, or a reduced form of a polyketone;
a printing mechanism for printing the solution of the prepolymer on a build plate to form a layer of the three-dimensional article; and
a printing controller to repeat the printing mechanism to print the solution of the prepolymer on a polymer formed by exposing the layer to a stimulus at a predetermined condition.

2. A method for manufacturing a three-dimensional article, the method comprising:
a. printing a solution of prepolymer on a build plate, wherein the prepolymer is a polysulfide, ketalized version of a polyketone, or a reduced form of a polyketone;
b. exposing the printed solution to a stimulus to form a polymer layer of the three-dimensional article; and
c. repeating the steps (a)-(b) to form remainder of the three-dimensional article.

3. The method of claim 2 , wherein stimulus comprises heat, light, oxidation, acid catalysis, base catalysis, transition metal catalysis, or combination thereof.

4. The method of claim 2 , wherein the steps are repeated after about 5 minutes to about 15 minutes.

5. The method of claim 2 , further comprising the step of curing wherein curing is done by chemical curing or thermal curing.

6. The method of claim 5 , wherein the thermal curing is carried out at about 300° C. or above.

Assignees

• Boydston Andrew J
• Ganter Mark
• Storti Duane
• Goetz Adam Edward
• Yurtoglu Mete
• Larsen Michael Byrnes
• Peterson Gregory Isaac
• Ricoh Co Ltd
• Univ Washington

Inventors

• Boydston Andrew J
• Ganter Mark
• Storti Duane
• Goetz Adam Edward
• Yurtoglu Mete
• Larsen Michael Byrnes
• Peterson Gregory Isaac

Classifications

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B29C64/106 Primary

  using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material · CPC title

• B33Y30/00 Primary

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title