# US 10,870,234 B2 · Methods and apparatus for 3d printing of highly viscous materials

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- Number: US 10,870,234 B2
- Document ID: US10870234B2
- Status: Granted
- Kind: B2
- Application number: 15/769,764
- Filed: 2017-11-07
- Published: 2019-09-19
- Granted: 2020-12-22
- Earliest claimed: 2016-11-08
- Assignees: Purdue Research Foundation
- Applicants: Purdue Research Foundation
- Inventors: Jeffrey Frederick Rhoads; Ibrahim Emre Gunduz; Steven Forrest Son; George Tsu-Chih Chiu
- Web page: https://patentgrep.com/patent/US10870234B2

## CPC

- B29C 64/209: Heads; Nozzles
- B05B 17/06: using ultrasonic {or other kinds of} vibrations
- B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM]
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- B29K 2103/08: Mineral aggregates, e.g. sand, clay or the like
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

This disclosure generally relates to methods and apparatus for 3D printing of highly viscous materials, especially to high amplitude ultrasonic vibration facilitated lower temperature 3D printing of highly viscous materials with a viscosity of at least 1000 Pa·s.

## Claims

### Claim 1

A three-dimensional (3D) printing method for highly viscous materials, wherein the method comprises:
a) providing a 3D printer comprising a reservoir, a nozzle, and a high amplitude ultrasonic vibration generator, wherein the high amplitude ultrasonic vibration generator is configured to generate an ultrasonic vibration through a vibration probe with an amplitude of 1-200 μm near the nozzle; and the nozzle is positioned at or in the close vicinity of a node of the ultrasonic vibration, wherein said vibration probe is not in physical contact with said reservoir and said nozzle;
b) providing a highly viscous material substantially free of any thinning material, wherein the highly viscous material has a viscosity of at least 1000 Pa·s and/or a solid content of at least 60%; and
c) 3D printing the highly viscous material at a temperature lower than 100° C. at the nozzle tip to provide a 3D printed material with a porosity of less than 10%.

### Claim 2 (depends on 1)

The method of claim 1, wherein the high amplitude ultrasonic vibration generator is configured to generate an ultrasonic vibration through a vibration probe with an amplitude of 1-200 μm near the tip of the nozzle; and the tip of the nozzle is positioned at or in the close vicinity of a node of the ultrasonic vibration.

### Claim 3 (depends on 1)

The method of claim 1, wherein the 3D printing temperature is lower than 50° C.

### Claim 4 (depends on 1)

The method of claim 1, wherein the 3D printed material has a porosity of less than 5%.

### Claim 5 (depends on 4)

The method of claim 4, wherein the 3D printed material has a porosity of less than 2%.

### Claim 6 (depends on 1)

The method of claim 1, wherein the 3D printing is carried out by applying a pressure under 1 MPa.

### Claim 7 (depends on 1)

The method of claim 1, wherein the 3D printed material has a 3D printing resolution of 100 μm or less.

### Claim 8 (depends on 1)

The method of claim 1, wherein the 3D printing is carried out with minimum or no support.

### Claim 9 (depends on 1)

The method of claim 1, wherein the vibration probe has a ring-shaped configuration to keep the nozzle run through and within the ring-shaped configuration to provide evenly distributed vibration.