Additive manufacturing system, method and corresponding components for making elastomeric structures

Patent metadata

Field	Value
Publication number	US-12415312-B2
Application number	US-202217707070-A
Country	US
Kind code	B2
Filing date	Mar 29, 2022
Priority date	Nov 12, 2018
Publication date	Sep 16, 2025
Grant date	Sep 16, 2025

Abstract

A system for additive manufacturing a medical device, the system comprising a first dispensing system, a second dispensing system, a deposition apparatus, and a deposition substrate on a surface of which the deposition apparatus is configured to deposit at least one elastomeric material into a filament. The deposition apparatus receives the at least one elastomeric material from the first and second dispensing systems in proportions effecting a desired property in the medical device. The deposition apparatus may comprise heating and/or cooling elements, a sonic vibration module, and/or a pneumatic suck-back valve. The deposition substrate may have a configuration corresponding to a desired shape of the medical device and is configured to rotate and/or translate relative to the deposition apparatus. The system comprises a controller configured to control the deposition.

First claim

The invention claimed is:

1. A system for additive manufacturing, comprising:
a dispensing system having a first reservoir containing a part A of an uncured liquid silicone material and further having a second reservoir containing a part B material of the uncured liquid silicone material, wherein the part A and the part B of the uncured liquid silicone material are curable to form a solid silicone structure;
a deposition apparatus comprising a nozzle, a first control valve, and a second control valve, the deposition apparatus arranged to receive the uncured liquid silicone material from the dispensing system; and
a deposition substrate configured to receive the uncured liquid silicone material deposited from the nozzle of the deposition apparatus, the deposition substrate having a cylindrical or conical mandrel;
a first actuator arranged to rotate the mandrel in a direction about a central axis of the mandrel;
a second actuator arranged to translate the mandrel along a rack in a first direction parallel to the central axis of the mandrel;
a third actuator configured to translate the deposition apparatus in at least one second direction as the deposition apparatus deposits the uncured liquid silicone material received onto the deposition substrate; and
wherein the deposition apparatus further comprises a dynamic mixer for mixing the uncured liquid silicone material;
wherein the deposition apparatus is arranged for advancing the part A from the first control valve along a first flow direction toward the part B provided from the second control valve, the deposition apparatus being further arranged for advancing both parts A and B in a combined, but unblended, flow along a second flow direction toward the dynamic mixer;
wherein the dynamic mixer comprises an impeller arranged to rotate within a flow channel and mix the uncured liquid silicone material under a constant pressure, the impeller including protrusions configured to actuate downward flow of the material parts A and B in the combined, but unblended, flow along the second flow direction toward the dynamic mixer through dynamic flow paths defined by and between the protrusions, the material parts A and B of the uncured liquid silicone material being mixed through the dynamic flow paths; and
wherein the deposition apparatus further comprises at least one pneumatic suck-back valve including a plunger configured to withdraw away from the flow channel, creating a negative pressure in a pneumatic stop line that draws the uncured liquid silicone material in the deposition apparatus away from the nozzle to form clean breaks between distinct filaments of the solid silicone structure after a discrete portion of the uncured liquid silicone material has been deposited on the deposition substrate.

2. The system for additive manufacturing of claim 1 , wherein the deposition apparatus comprises a sonic vibration module.

3. The system for additive manufacturing of claim 1 , wherein the deposition apparatus further comprises at least one heating and/or cooling element.

4. The system for additive manufacturing of claim 1 , wherein the deposition apparatus comprises a sonic vibration module upstream in the flow channel leading to the nozzle.

5. The system for additive manufacturing of claim 1 , wherein the deposition apparatus comprises at least one temperature sensor and at least one pressure sensor.

6. The system for additive manufacturing of claim 1 , wherein the deposition apparatus includes at least one proportioning device.

7. The system for additive manufacturing of claim 1 , further comprising:
a feed component receiving the uncured liquid silicone material from the dispensing system and transferring the uncured liquid silicone material from the dispensing system to the deposition apparatus, the feed component including a displacement pump arranged to transfer the uncured silicone to the deposition apparatus;
wherein the displacement pump includes piston rods configured to receive the uncured liquid silicone material without blending or affecting the order of the liquid silicone material being accumulated within the displacement pump, and wherein the uncured liquid silicone material is conducted toward the deposition apparatus when the piston rods are driven toward the deposition apparatus.

8. The system for additive manufacturing of claim 1 , wherein the deposition apparatus is arranged to deposit the uncured liquid silicone material onto the mandrel as the mandrel rotates.

Assignees

• Ossur Iceland Ehf

Inventors

• Asgeirsson Sigurdur
• Dlab Jiri
• Sigfusson Larus

Classifications

• B29K2021/00

  Use of unspecified rubbers as moulding material · CPC title

• B33Y30/00

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

• B29C64/307

  Handling of material to be used in additive manufacturing · CPC title

• B29C64/106

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

• B29C64/227

  Driving means · CPC title