Additive manufacturing method to achieve three dimensional parts having superior properties
AssigneeHenkel AG & Co. KGaA
InventorsNick Talken, Stefan Hinote
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Abstract
Additive manufacturing methods to achieve three dimensional parts having superior properties are provided herein.
Claims56
A method for performing additive manufacturing using a photocurable composition to form a three-dimensional part, said three-dimensional part made according to data indicating a pre-determined pattern, comprising the steps of:
- A. Providing a photocurable composition in a non-flowable state to a reservoir, wherein the photocurable composition comprises a solid functionalized component;
- B. Subjecting the photocurable composition to conditions favorable to render the photocurable composition in a flowable state;
- and
- C. Exposing the flowable photocurable composition to radiation in the electromagnetic spectrum appropriate to initiate polymerization thereof as the three-dimensional printed part is made according to data indicating a pre-determined pattern, wherein in step B the photocurable composition is exposed to a temperature of between about 45° C. to about 160° C. and
- in step C the photocurable composition is exposed to a temperature of about 45° C. to about 160° C.
A method for performing additive manufacturing using a photocurable composition to form a three-dimensional part, said three-dimensional part made according to data indicating a pre-determined pattern, comprising the steps of:
- A. Providing a photocurable composition in a non-flowable state to a reservoir;
- B. Subjecting the photocurable composition to conditions favorable to render the photocurable composition in a flowable state;
- and
- C. Exposing the flowable photocurable composition to radiation in the electromagnetic spectrum appropriate to initiate polymerization thereof as the three-dimensional printed part is made according to data indicating a pre-determined pattern, wherein in step B and/or step C the photocurable composition has a vapor pressure less than about 1 mm Hg,
- wherein in step B the photocurable composition is exposed to a temperature of between about 45° C. to about 160° C. and
- in step C the photocurable composition is exposed to a temperature of between about 45° C. to about 160° C.
A method for performing additive manufacturing using a photocurable composition to form a three-dimensional part, said three-dimensional part made according to data indicating a pre-determined pattern, comprising the steps of:
- A. Providing a photocurable composition in a non-flowable state to a reservoir;
- B. Subjecting the photocurable composition to conditions favorable to render the photocurable composition in a flowable state;
- and
- C. Exposing the flowable photocurable composition to radiation in the electromagnetic spectrum appropriate to initiate polymerization thereof as the three-dimensional printed part is made according to data indicating a pre-determined pattern, wherein in step A the photocurable composition comprising a solid functionalized component demonstrates a phase change from solid to liquid within a 5° C. increase in temperature measured by DSC over a period of time of 20 minutes.
A method for performing additive manufacturing using a photocurable composition to form a three-dimensional part, said three-dimensional part made according to data indicating a pre-determined pattern, comprising the steps of:
- A. Providing a photocurable composition in a non-flowable state to a reservoir;
- B. Subjecting the photocurable composition to conditions favorable to render the photocurable composition in a flowable state;
- and
- C. Exposing the flowable photocurable composition to radiation in the electromagnetic spectrum appropriate to initiate polymerization thereof as the three-dimensional printed part is made according to data indicating a pre-determined pattern, wherein the three-dimensional part formed in step C has a heat deflection temperature (@0.455 MPa) at least as high as the elevated temperature of step B and/or step C,
- wherein in step B the photocurable composition is exposed to a temperature of between about 45° C. to about 160° C. and
- in step C the photocurable composition is exposed to a temperature of between about 45° C. to about 160° C.
A method for performing additive manufacturing using a photocurable composition to form a three-dimensional part, said three-dimensional part made according to data indicating a pre-determined pattern, comprising the steps of:
- A. Providing a photocurable composition in a non-flowable state to a reservoir;
- B. Subjecting the photocurable composition to conditions favorable to render the photocurable composition in a flowable state;
- and
- C. Exposing the flowable photocurable composition to radiation in the electromagnetic spectrum appropriate to initiate polymerization thereof as the three-dimensional printed part is made according to data indicating a pre-determined pattern, wherein the three-dimensional part formed after step C achieves at least about 50% of at least one of its ultimate strength, its ultimate stiffness and its ultimate heat deflection temperature,
- wherein in step B the photocurable composition is exposed to a temperature of between about 45° C. to about 160° C. and
- in step C the photocurable composition is exposed to a temperature of between about 45° C. to about 160° C.
A method for performing additive manufacturing using a photocurable composition to form a three-dimensional part having superior physical properties, said three-dimensional part made according to data indicating a pre-determined pattern, comprising the steps of:
- A. Providing a photocurable composition in a non-flowable state to a reservoir;
- B. Subjecting the photocurable composition to a temperature condition favorable to render the photocurable composition in a flowable state, wherein the temperature condition is between about 45° C. and about 160° C.;
- C. Exposing the flowable photocurable composition to radiation in the electromagnetic spectrum appropriate to initiate polymerization thereof as the three-dimensional printed part is made according to data indicating a pre-determined pattern, wherein in step C the photocurable composition is exposed to a temperature of between about 45° C. and about 160° C.;
- and
- D. Exposing the three-dimensional part formed in step C to an elevated temperature condition that is greater than the temperature condition to which the photocurable composition is exposed in step B and/or step C.
Dependencies are inferred from the claim text.