# US 11,305,458 B2 · Process for producing a cured 3D product

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- Number: US 11,305,458 B2
- Document ID: US11305458B2
- Status: Granted
- Kind: B2
- Application number: 16/712,275
- Filed: 2019-12-12
- Published: 2020-06-18
- Granted: 2022-04-19
- Earliest claimed: 2018-12-17
- Assignees: What the Future Venture Capital (Wtfvc) B.V.
- Applicants: What the Future Venture Capital (Wtfvc) B.V.
- Inventors: Janne Tuomas Kyttanen
- Web page: https://patentgrep.com/patent/US11305458B2

## CPC

- B28B 7/342: {which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not}
- B22F 10/12: by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
- B28B 1/30: by applying the material on to a core or other moulding surface to form a layer thereon (to form a permanent layer B28B19/00)
- B28B 7/0029: {Moulds or moulding surfaces not covered by B28B7/0058 - B28B7/36 and B28B7/40 - B28B7/465, e.g. moulds assembled from several parts}
- B28B 7/346: {Manufacture of moulds}
- B28B 7/348: {of plastic material or rubber}
- B28B 11/24: for curing, setting or hardening (processes for influencing or modifying the setting or hardening ability of mortars, concrete or artificial stone compositions, in general C04B40/00)
- B28B 11/241: {using microwave heating means}
- B28B 11/243: {Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence)}
- B29C 33/0011: {thin-walled moulds}
- B29C 33/34: movable, e.g. to or from the moulding station
- B29C 33/3842: {Manufacturing moulds, e.g. shaping the mould surface by machining}
- B29C 35/0805: {using electromagnetic radiation}
- B29C 39/04: using movable moulds (B29C41/02 takes precedence){not applied}
- B29C 39/26: Moulds or cores
- B29C 51/00: Shaping by thermoforming {, i.e. shaping sheets or sheet like preforms after heating}, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor {(blow moulding of tubular preforms B29C49/00, deforming of tubular or hollow preforms B29C67/0014)}
- B29C 51/002: {characterised by the choice of material}
- B29C 51/105: {Twin sheet thermoforming, i.e. deforming two parallel opposing sheets or foils at the same time by using one common mould cavity and without welding them together during thermoforming (B29C51/267, B29C49/0691 take precedence)}
- B29C 51/30: Moulds
- B33Y 10/00: Processes of additive manufacturing
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- C04B 35/622: Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B 35/632: Organic additives
- C08F 12/08: Styrene
- B22F 12/41: characterised by the type, e.g. laser or electron beam
- B22F 2998/10: Processes characterised by the sequence of their steps
- B29C 35/08: by wave energy or particle radiation {(B29C64/00, B29C71/04 take precedence)}
- B29C 2035/0827: {using UV radiation}
- B29C 2035/0855: {using microwave}
- B29C 2791/006: Using vacuum
- B29K 2021/00: Use of unspecified rubbers as moulding material
- B29K 2023/06: {PE, i.e. polyethylene}
- B29K 2023/12: {PP, i.e. polypropylene}
- B29K 2025/06: {PS, i.e. polystyrene}
- B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material
- B29K 2069/00: Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- B29K 2503/06: Metal powders, metal carbides or the like
- B29K 2509/02: Ceramics
- B29K 2995/0027: for light outside the visible spectrum
- C04B 2235/602: Making the green bodies or pre-forms by moulding
- C04B 2235/6027: Slip casting
- C04B 2235/667: Sintering using wave energy, e.g. microwave sintering
- C04B 2235/94: Products characterised by their shape
- Y02P 10/25: Process efficiency
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- 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)
- 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
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- 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
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The invention is directed to a process for producing a cured 3D product comprising the following steps: (a) providing a form negative mould of the 3D product comprising of one or two formed plastic sheets as obtained by thermoforming corresponding with the shape of the 3D product; (b) adding a liquid curable composition to the mould such that the inner surface of the mould is covered by the curable composition; and (c) solidifying the curable composition wherein a solidified layer or body is formed having the shape of the 3D product; wherein the cured 3D product is a radiation cured 3D product; and wherein the step (c) a radiation curable composition is solidified by radiation through the plastic sheet of the mould to form a solidified layer having the shape of the 3D product.

## Claims

### Claim 1

Process for producing a radiation cured 3D product comprising the following steps:
(a) providing a form negative mould of the 3D product comprising of one or two formed plastic sheets as obtained by thermoforming corresponding with the shape of the 3D product,
(b) adding a liquid radiation curable composition to the form negative mould such that the inner surface of the form negative mould is covered by the liquid radiation curable composition, and
(c) solidifying the liquid radiation curable composition by radiation through the formed plastic sheet of the form negative mould to form a solidified layer or body having the shape of the radiation cured 3D product.

### Claim 2 (depends on 1)

Process according to claim 1, wherein the formed plastic sheet is obtained by a continuous thermoforming process using a thermoforming packaging machine.

### Claim 3 (depends on 2)

Process according to claim 2, wherein the mould is comprised of two formed plastic sheets or the mould is comprised of one formed plastic sheet and one planar sheet.

### Claim 4 (depends on 3)

Process according to claim 3, wherein the thermoforming packaging machine comprises of one or two thermoforming stations and a sealing station and wherein in the thermoforming station a formed intermediate sheet is obtained, wherein in the sealing station this formed intermediate sheet is combined with a planar sheet or with another formed intermediate sheet obtained in the optional second thermoforming station to obtain the form negative mould of the 3D product.

### Claim 5 (depends on 1)

Process according to claim 1, wherein in step (b) the mould is filled with the radiation curable composition and wherein in step (c) part of the radiation curable composition is solidified as the solidified layer and wherein after solidification of the radiation curable composition any non-solidified radiation curable composition is removed from the mould.

### Claim 6 (depends on 1)

Process according to claim 1, wherein the radiation in step (c) is microwave radiation resulting in that the liquid radiation curable composition cures due to dielectric heating.

### Claim 7 (depends on 1)

Process according to claim 1, wherein the liquid radiation curable composition is a photocurable ceramic dispersion.

### Claim 8 (depends on 7)

Process according to claim 7, wherein in a step (d) the solidified layer or body is sintered thereby obtaining a sintered ceramic 3D product.

### Claim 9 (depends on 8)

Process according to claim 8, wherein prior to step (d) the form negative mould is separated from the solidified layer or body having the shape of the 3D product.

### Claim 10 (depends on 1)

Process according to claim 1, wherein the plastic is a thermoplastic polymer.

### Claim 11 (depends on 10)

Process according to claim 10, wherein the plastic is polystyrene.

### Claim 12

Process for producing a radiation cured sintered ceramic 3D product comprising the following steps:
(a) providing a form negative mould of the 3D product comprising of one or two formed plastic sheets as obtained by thermoforming corresponding with the shape of the 3D product,
(b) adding a liquid photocurable ceramic dispersion to the form negative mould such that the inner surface of the form negative mould is covered by the liquid photocurable ceramic dispersion,
(c) solidifying the liquid photocurable ceramic dispersion by radiation through the plastic sheet of the form negative mould to form a solidified layer or body, and
(d) sintering the solidified layer or body and thereby obtaining a radiation cured sintered ceramic 3D product, wherein the formed plastic sheet is obtained by a continuous thermoforming process using a thermoforming packaging machine.