Ink compositions for three-dimensional printing and methods of forming objects using the ink compositions

Patent metadata

Field	Value
Publication number	US-2017081534-A1
Application number	US-201515310858-A
Country	US
Kind code	A1
Filing date	May 15, 2015
Priority date	May 15, 2014
Publication date	Mar 23, 2017
Grant date	—

Abstract

3D printable ink compositions for forming objects, films and coatings are provided. Also provided are methods of printing the ink compositions and methods for making the ink compositions. The ink compositions include an elastic polymer binder and may have high loadings of solid particles.

First claim

What is claimed is:

1 . An ink composition comprising:
a solvent system comprising at least about 50 vol. % dichloromethane, chloroform, or a mixture thereof and at least one additional organic solvent having a lower vapor pressure at 23° C. than the dichloromethane, chloroform, or a mixture thereof; a polyester polymer that is soluble in the solvent system at 23° C.; and solid particles that are insoluble in the solvent system at 23° C.; wherein the ink composition comprises at least about 50 vol. % of solid particles based on its solids content.

2 . The composition of claim 1 , wherein the solvent system comprises dichloromethane.

3 . The composition of claim 1 comprising at least two different types of particles, wherein the different types of particles comprise different materials.

4 . The composition of claim 3 , wherein the solid particles comprise particles comprising an organic material and particles comprising an inorganic material.

5 . The composition of claim 3 , wherein the different types of particles comprise particles selected from at least two of the following particle types: metal oxide particles, particles of oxides of non-metal elements, metal particles, metal alloy particles, polymer particles, bioceramic particles, carbon particles, salt particles, particles derived from biological sources and natural soil particles.

6 . The composition of claim 1 comprising at least two different types of particles, wherein average smallest dimension for one of the at least two different types of particles is less than 1000 nm and the average smallest dimension for the other of the at least two different types of particles is greater than 1000 nm.

7 . The composition of claim 1 comprising at least two different types of particles, wherein the two different types of particles have two different shapes independently selected from cylindrical, substantially spherical and plate-like.

8 . The composition of claim 1 , wherein the solid particles comprise metal oxide particles.

9 . The composition of claim 1 , wherein the solid particles comprise metal particles.

10 . The composition of claim 1 , wherein the solid particles comprise bioceramic particles.

11 . The composition of claim 1 , wherein the solid particles comprise graphene particles.

12 . The composition of claim 1 , wherein the solid particles comprise planetary soil particles.

13 . The composition of claim 1 , wherein the ink composition comprises at least about 70 vol. % solid particles based on its solids content.

14 . The composition of claim 2 , wherein the solvent system comprises at least two additional organic solvents, one of which is an organic surfactant and the other of which is a plasticizer.

15 . The composition of claim 14 , wherein the two additional organic solvents are 2-butoxyethanol and dibutylphthalate.

16 . The composition of claim 15 , wherein the polyester polymer comprises polylactic-co-glycolic acid.

17 . The composition of claim 1 , wherein the polyester polymer comprises polylactic-co-glycolic acid.

18 . The composition of claim 1 , wherein the polyester polymer comprises polycaprolactone.

19 . The composition of claim 1 , wherein the polyester polymer comprises polylactic acid.

20 . The composition of claim 1 , wherein the polyester polymer comprises glycolic acid.

21 . A method of forming a three-dimensional printed object, the method comprising:
(a) extruding an ink composition through a nozzle to form a printed layer, the ink composition comprising:
a solvent system comprising at least about 50 vol. % of a primary organic solvent having a vapor pressure in the range from 20 to 60 kPa at 23° C. and atmosphereic pressure, and at least one additional organic solvent having a lower vapor pressure at 23° C. and atmospheric pressure than the primary organic solvent;
a polyester polymer that is soluble in the solvent system at 23° C.; and
solid particles that are insoluble in the solvent system at 23° C.;
wherein the ink composition comprises at least about 50 vol. % of solid particles based on its solids content;
(b) repeating step (a) to form a printed object comprising multiple, vertically stacked printed layers.

22 . The method of claim 21 , wherein the primary organic solvent is dichloromethane.

23 . The method of claim 21 , wherein step (a) is repeated at least nine times to form a printed object comprising at least 10 vertically stacked printed layers.

24 . The method of claim 23 , wherein the architecture of the printed object is defined by one or more computer aided design drawings.

25 . The method of claim 21 , wherein the object has an aspect ratio of at least 10:1.

26 . The method of claim 21 , wherein at least one of the printed layers is printed over an open space, such that the printed object has at least one hollow portion.

27 . The method of claim 21 , wherein the extrusion is carried out at room temperature.

28 . The method of claim 21 , wherein the elastomeric polymer comprises a polyester polymer.

29 . The method of claim 21 , wherein the printed layers and the printed object can be handled within 3 seconds or less of printing without being deformed.

30 . A method of forming a multi-part, three-dimensional printed object, the method comprising:
(a) forming a first three-dimensional printed object using the method of claim 18 ; (b) forming a second three-dimensional printed object using the method of claim 18 ; (c) applying the ink composition used to make the first or second three-dimensional printed objects to a surface of at least one of the first or second three-dimensional printed objects; (d) contacting the other of the first or second three-dimensional printed objects to the applied ink composition; and (e) allowing the solvents in the solvent system to evaporate to form the multi-part, three-dimensional object comprising the first three-dimensional printed object bonded to the second three-dimensional printed object.

Assignees

• Univ Northwestern

Inventors

• Shah Ramille N
• Jakus Adam E

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C09D11/037

  characterised by the pigment · CPC title

• B29K2507/04

  Carbon · CPC title

• C09D11/033

  characterised by the solvent · CPC title

• B29K2511/00

  Use of natural products or their composites, not provided for in groups {B29K2401/00 - B29K2509/00,} as filler · CPC title