System and method for forming integrated interfaces within a three-dimensionally printed object with different build materials
AssigneeXerox Corporation
InventorsBarry P. Mandel, Paul J. McConville, Peter J. Nystrom, Jeffrey J. Folkins, David A. Mantell
Life of this patent
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Abstract
An additive manufacturing system operates at least one ejector and an extruder to form three-dimensional objects with photopolymer material and thermoplastic material. The system operates to deposit the two materials in a layer-by-layer manner. The photopolymer material provides high resolution finishes on the objects and the thermoplastic material enables strong and stable formation of internal portions of the objects.
Claims26
An additive manufacturing method for producing three-dimensional objects with multiple materials comprising:
- operating with a controller at least one ejector in a plurality of ejectors to eject drops of a photopolymer material towards a substrate, the drops of photopolymer material being formed with a perimeter portion that extends above a base portion so the perimeter portion and the base portion define a volume;
- operating with the controller a source of ultraviolet (UV) radiation to cure the drops of photopolymer material at least partially;
- operating with the controller an extruder to extrude a thermoplastic material within the volume defined by base portion and the perimeter portion;
- operating with the controller the at least one ejector to eject additional photopolymer material onto the thermoplastic material to form a surface over at least a portion of the thermoplastic material;
- and
- operating with the controller the source of UV radiation to cure the drops of photopolymer material and the additional photopolymer material.
An additive manufacturing system for producing three-dimensional objects with multiple materials comprising:
- a planar member;
- at least one ejector configured to eject drops of photopolymer material towards the planar member;
- a source of ultraviolet (UV) radiation;
- an extruder configured to extrude thermoplastic material towards the planar member;
- and
- a controller operatively connected to the at least one ejector, the source of UV radiation, and the extruder, the controller being configured to:
- operate at least one ejector in a plurality of ejectors to eject drops of a photopolymer material towards the planar member, the drops of photopolymer materials forming a perimeter portion that extends above a base portion so the perimeter portion and the base portion define a volume;
- operate the source of UV radiation to cure the drops of photopolymer material at least partially;
- operate the extruder to extrude a thermoplastic material within the volume of the defined by the base portion and the perimeter portion of the at least partially cured photopolymer material;
- operate the at least one ejector to eject additional photopolymer material onto the thermoplastic material to form a surface over at least a portion of the thermoplastic material;
- and
- operate the source of UV radiation to cure the drops of photopolymer material and the additional photopolymer material.
Dependencies are inferred from the claim text.