Build material and applications thereof

Patent metadata

Field	Value
Publication number	US-9394441-B2
Application number	US-201113043876-A
Country	US
Kind code	B2
Filing date	Mar 9, 2011
Priority date	Mar 9, 2011
Publication date	Jul 19, 2016
Grant date	Jul 19, 2016

Abstract

In one aspect, build materials operable for use in 3D printing systems are described herein. In some embodiments, a build material comprises an oligomeric curable material, a reactive component that is solid at 25° C., and at least one diluent, wherein the reactive component comprises at least one chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material and/or the at least one diluent.

First claim

That which is claimed:

1. A build material for use in a three-dimensional printing system comprising:
an oligomeric curable material;
a reactive component;
a non-reactive component comprising one or more urethane waxes; and
at least one diluent,

wherein the reactive component comprises at least one chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material and/or the at least one diluent and wherein the reactive component is present in the build material as crystalline regions.

2. The build material of claim 1 , wherein the non-reactive component does not comprise a chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material or the at least one diluent.

3. The build material of claim 1 , wherein the build material further comprises one or more additives selected from the group consisting of photoinitiators, inhibitors, stabilizing agents, sensitizers, and combinations thereof.

4. The build material of claim 1 , wherein the oligomeric curable material is a urethane (meth)acrylate having a viscosity ranging from about 10,000 cps to about 300,000 cps.

5. The build material of claim 1 , wherein the oligomeric curable material and the reactive component each contain one or more acrylate or (meth)acrylate moieties.

6. The build material of claim 1 , wherein the reactive component is solid at about 30° C.

7. The build material of claim 1 , wherein the reactive component is solid at about 40° C.

8. The build material of claim 1 , wherein the reactive component is crystalline or substantially crystalline at about 30° C.

9. The build material of claim 1 , wherein the reactive component is crystalline or substantially crystalline at about 40° C.

10. The build material of claim 1 , wherein the reactive component is crystalline or substantially crystalline at about 50° C.

11. The build material of claim 1 , wherein the reactive component comprises more than one chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material and/or the at least one diluent.

12. The build material of claim 1 , wherein the reactive component comprises at least one of the following: a urethane (meth)acrylate, a urea (meth)acrylate, and an isocyanurate (meth)acrylate.

13. The build material of claim 1 , wherein the reactive component is selected from the group consisting of:
(i) an isocyanurate tri(meth)acrylate;
(ii) a species defined by the formula R 1 —NHCOO—R 2 —R 3 , wherein R 1 is C n H (2n+2) (wherein n=4-36), R 2 is C n H (2n+2) (wherein n=2-36), and R 3 is —OCOCH═CH 2 or —OCOC(CH 3 )═CH 2 ;
(iii) a species defined by the formula R 1 —R 2 —NHCOO—R 3 —OOC—NH—R 2 —R 1 , wherein R 1 is —OCOCH═CH 2 or —OCOC(CH 3 )═CH 2 , R 2 is C n H (2n+2) (wherein n=2-36), and R 3 is C n H (2n+2) (wherein n=2-36);
(iv) a species defined by the formula R 1 —NHCONH—R 2 —R 3 , wherein R 1 is C n H (2n+2) (wherein n=4-36), R 2 is C n H (2n+2) (wherein n=2-36), and R 3 is —OCOCH═CH 2 or —OCOC(CH 3 )═CH 2 ; and
(v) a species defined by the formula R 1 —R 2 —NHCONH—R 3 —OOC—NH—R 2 —R 1 , wherein R 1 is —OCOCH═CH 2 or —OCOC(CH 3 )═CH 2 , R 2 is C n H (2n+2) (wherein n=2-36), and R 3 is C n H (2n+2) (wherein n=2-36).

14. The build material of claim 1 , wherein the reactive component comprises a nitrogen-containing ring.

15. The build material of claim 1 , wherein the reactive component is an isocyanurate.

16. The build material of claim 1 , wherein the reactive component is tris(2-hydroxy ethyl)isocyanurate triacrylate.

17. The build material of claim 1 , wherein the reactive component comprises about 5 to about 50 percent by weight of the build material.

18. The build material of claim 1 , wherein the reactive component comprises about 5 to about 30 percent by weight of the build material.

19. The build material of claim 1 , wherein the reactive component comprises about 5 to about 15 percent by weight of the build material.

20. The build material of claim 1 , wherein the reactive component exhibits a melting point range of about 1° C. to about 10° C.

21. The build material of claim 1 , wherein the reactive component exhibits a melting point range centered between about 40° C. and about 100° C.

22. The build material of claim 1 , wherein the at least one diluent contains one or more (meth)acrylate moieties.

23. The build material of claim 1 , wherein the build material when cured exhibits a tensile modulus of about 1500-2200 MPa when measured according to ASTM D 638.

24. The build material of claim 1 , wherein the build material when cured exhibits a tensile modulus of about 1500-1900 MPa when measured according to ASTM D 638.

25. The build material of claim 1 , wherein the build material when cured exhibits a tensile modulus of about 1550-1850 MPa when measured according to ASTM D 638.

26. The build material of claim 1 , wherein the build material when cured exhibits a break elongation of about 10-24% when measured according to ASTM D 638.

27. The build material of claim 1 , wherein the build material when cured exhibits a break elongation of about 12-22% when measured according to ASTM D 638.

28. The build material of claim 1 , wherein the build material when cured exhibits a break elongation of about 14-20% when measured according to ASTM D 638.

29. The build material of claim 1 , wherein the build material when cured exhibits a heat deflection temperature ranging from about 45° C. to about 100° C. when tested according to ASTM D 648.

30. The build material of claim 1 , wherein the build material exhibits a melting point range centered between about 45° C. and about 55° C.

31. The build material of claim 1 , wherein the build material exhibits a melting point range centered between about 50° C. and about 65° C.

32. The build material of claim 1 , wherein the build material exhibits a melting point range centered between about 50° C. and about 80° C.

33. The build material of claim 1 , wherein the build material exhibits a melting point range centered at a temperature greater than about 40° C.

34. A composition comprising:
a three-dimensionally printed article comprising a build material, the build material comprising an oligomeric curable material, a reactive component, a non-reactive component comprising one or more urethane waxes, and at least one diluent, wherein the reactive component comprises at least one chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material and/or the at least one diluent and wherein the reactive component is present in the build material as crystalline regions.

35. The composition of claim 34 , wherein the non-reactive component does not comprise a chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material or the at least one diluent.

36. The composition of claim 34 , wherein the reactive component is substantially crystalline at 25° C.

37. The composition of claim 34 , wherein the reactive component comprises more than one chemical moiety that is polymerizable with a chemical moiety contained in the oligomeric curable material and/or t

Assignees

• Xu Pingyong
• Stockwell John
• 3D Systems Inc

Inventors

• Xu Pingyong
• Stockwell John

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B29C64/40

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• C08L75/16 Primary

  having terminal carbon-to-carbon unsaturated bonds · CPC title

• C09D11/101

  Inks specially adapted for printing processes involving curing by wave energy or particle radiation, e.g. with UV-curing following the printing · CPC title

• C09D11/34

  Hot-melt inks · CPC title