Method of manufacturing three-dimensional object, liquid set for manufacturing three-dimensional object, device for manufacturing three-dimensional object, and gel object

Patent metadata

Field	Value
Publication number	US-10882245-B2
Application number	US-201615194934-A
Country	US
Kind code	B2
Filing date	Jun 28, 2016
Priority date	Jul 6, 2015
Publication date	Jan 5, 2021
Grant date	Jan 5, 2021

Abstract

A method of manufacturing a three-dimensional object includes imparting a first liquid having a first composition including a solvent and a curable material and a second liquid having a second composition to form a liquid film, curing the liquid film, and repeating the imparting and the curing to obtain the three-dimensional object, wherein the imparting position and the imparting amount of each of the first liquid and the second liquid are controlled in such a manner that the liquid film includes multiple areas where at least one of post-curing compression stress and post-curing modulus of elasticity is different.

First claim

What is claimed is:

1. A method of manufacturing a three-dimensional object, comprising:
discharging onto a stage a first liquid for forming the three-dimensional object from a first discharging head, a second liquid for forming the three-dimensional object from a second discharging head, and a third liquid for forming a support structure from a third discharging head, such that the discharged first and second liquids are mixed on the stage and multiple areas having different mixing ratios of the first and second liquids are formed on the stage, and that the third liquid is imparted to a site where the first liquid or the second liquid is not imparted,
wherein
the first liquid comprises water, a curable material, and a polymerization initiator,
the second liquid comprises a solvent to dilute the first liquid, and
the third liquid is free of water and has a composition different from compositions of the first liquid and second liquid;

curing the mixtures of the first and second liquids, and the third liquid, on the stage;
repeating the discharging and the curing to obtain the three-dimensional object that is supported by the support structure; and
removing the support structure from the three-dimensional object,
wherein after the curing, the multiple areas having different mixing ratios of the first and second liquids have different compression stress, modulus of elasticity, or both.

2. The method according to claim 1 , wherein an amount of the first liquid discharged from the first discharging head and an amount of the second liquid discharged from the second discharging head are controlled based on a volume of a droplet or a number of droplets discharged from the first or second discharging head.

3. The method according to claim 1 , wherein the second liquid is free of a curable material.

4. The method according to claim 1 , wherein the curable material in the first liquid is acryloyl morpholine.

5. The method according to claim 3 , wherein the curable material in the first liquid is acryloyl morpholine.

6. A method of manufacturing a three-dimensional object, comprising:
discharging onto a stage a first liquid for forming the three-dimensional object from a first discharging head and a second liquid for forming the three-dimensional object from a second discharging head, and a third liquid for forming a support structure from a third discharging head, such that the discharged first and second liquids are mixed on the stage and that a liquid film having multiple areas having different mixing ratios of the first and second liquids are formed on the stage, and that the third liquid is imparted to a site where the first liquid or the second liquid is not imparted;
where the first liquid comprises water, a curable material, and a polymerization initiator, and the second liquid comprises a solvent to dilute the first liquid; and the third liquid is free of water and has a composition different from compositions of the first liquid and second liquid;
curing the liquid film and the third liquid, on the stage; and
repeating the discharging and the curing to obtain the three-dimensional object that is supported by the support structure,
removing the support structure form the three-dimensional object
wherein 80 percent compressive stress-strain, modulus of elasticity, or both, of the three-dimensional object has a continuous gradient, and
the three-dimensional object is an internal organ model.

7. The method according to claim 1 , wherein the first liquid further comprises a mineral.

8. The method according to claim 1 , wherein the first liquid further comprises a cross-linking agent.

9. The method according to claim 1 , wherein in the discharging, the first, second, and third liquids are discharged directly onto the stage.

10. The method according to claim 1 , wherein the repeating of the discharging and the curing is performed such that the first, second, and third liquid are discharged on a cured first, second, and third liquids on the stage.

11. The method according to claim 1 , wherein the repeating of the discharging and the curing is performed such that the obtained three-dimensional object is a laminate of layers obtained by curing the first and second liquids in the curing.

12. The method according to claim 1 ,
wherein the discharging is performed such that at least four areas having different mixing ratios of the first and second liquids are formed on the stage, and
after the curing, the at least four areas having different mixing ratios of the first and second liquids have different compression stress, modulus of elasticity, or both.

13. The method according to claim 1 ,
wherein the discharging is performed by using a device having a discharging head consisting of the first discharging head, the second discharging head, and the third discharging head.

14. The method according to claim 1 , wherein the three-dimensional object is an internal organ model.

Assignees

• Iwata Hiroshi
• Norikane Yoshihiro
• Matsumura Takashi
• Niimi Tatsuya
• Naito Hiroyuki
• Ricoh Co Ltd

Inventors

• Iwata Hiroshi
• Norikane Yoshihiro
• Matsumura Takashi
• Niimi Tatsuya
• Naito Hiroyuki

Classifications

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29K2105/0073

  Solution · CPC title