# US 2019/0168448 A1 · Complex Shaped 3D Objects Fabrication

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- Number: US 2019/0168448 A1
- Document ID: US20190168448A1
- Status: Published application
- Kind: A1
- Application number: 15/960,584
- Filed: 2018-04-24
- Published: 2019-06-06
- Earliest claimed: 2017-12-06
- Assignees: Massivit 3D Printing Technologies Ltd
- Applicants: Massivit 3D Printing Technologies Ltd.
- Inventors: Ricardo Osiroff; Moshe Uzan; Igor Yakubov; Shai Garty; Cesar Manna
- Web page: https://patentgrep.com/patent/US20190168448A1

## CPC

- B29C 64/124: using layers of liquid which are selectively solidified
- B29C 33/3842: {Manufacturing moulds, e.g. shaping the mould surface by machining}
- B29C 39/026: {characterised by the shape of the surface}
- B29C 39/34: for undercut articles
- B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C 64/209: Heads; Nozzles
- B29C 64/236: for motion in a direction within the plane of a layer
- B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40)
- B29C 64/393: for controlling or regulating additive manufacturing processes
- B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B29C 33/38: characterised by the material or the manufacturing process (B29C33/44 takes precedence)
- B29C 33/3835: {Designing moulds, e.g. using CAD-CAM}
- B29C 39/003: {characterised by the choice of material}
- B29C 39/006: {Monomers or prepolymers (by reaction injection moulding B29C67/246)}
- B29C 64/241: for rotary motion
- B29C 2033/385: {by laminating a plurality of layers}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 50/02: for controlling or regulating additive manufacturing processes
- 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

## Abstract

A method and apparatus for manufacturing of 3D objects. The apparatus includes a number of material deposition heads terminated by nozzles, of which one or two nozzles are configured to deposit a first material to form a first and second pattern layers. The pattern layers are laterally shifted from each other such that when the first and second pattern layers are deposited, a space (empty volume) with a varying cross section is formed. In some examples, two or more nozzles could be used to deposit the corresponding first and second pattern layers. The nozzles could move independent of each other.

## Claims

### Claim 1

A method comprising:
employing a first polymeric material to deposit first and second pattern layers laterally shifted from each other such that laterally shifted pattern layers form between them an empty volume with a variable cross section that varies along the first and second pattern layers;
casting in the empty volume between the first and second pattern layers a second polymeric material to cast a complex shaped 3D object identical in shape to the empty volume between the first and second pattern layers;
applying radiation to cure the second polymeric material and removing the first and the second pattern layers to complete manufacture of the cast complex shaped 3D object identical in shape to the empty volume between the first and second pattern layers;
exposing the first polymeric material to water to cause it swell and break into beads, and washing out the beads with excess of water to remove the first and second pattern layers from the complex shaped 3D object.

### Claim 2 (depends on 1)

The method according to claim 1 further comprising casting the second polymeric material following curing of the first polymeric material.

### Claim 3

(canceled)

### Claim 4 (depends on 1)

The method according to claim 1 wherein composition of the first polymeric material includes hydrophilic monomers combined with hydrophilic or hydrophobic crosslinkers.

### Claim 5 (depends on 1)

The method according to claim 1 wherein composition of the first polymeric material includes acrylamide, methacrylamide, acrylate, acrylic acids and its salts, hydroxy(meth)acrylate, carboxy(meth)acrylate, acrylonitrile, carbohydrate monomers, methacrylate and polyfunctional acrylics.

### Claim 6 (depends on 1)

The method according to claim 1 wherein composition of the first polymeric material further includes poly(ethylene glycol) (PEG), of molecular weight (MW), from ethylene glycol of 62 Dalton, through oligomers of MW between 100 Dalton to 10,000 Dalton and up to high molecular weight polymers from 10,000 to 300,000 Dalton.

### Claim 7 (depends on 1)

The method according to claim 1 wherein the second polymeric material is a thermosetting polymer material.

### Claim 8 (depends on 7)

The method according to claim 7 wherein the second polymeric material includes at least one of a group of materials consisting of epoxy resins, vinylesters, polyesters, acrylates, polyurethanes, polyurea, vulcanized rubber, phenol-formaldehyde, urea-formaldehyde, melamine resin, benzoxazines, polyimides, bismaleimides, cyanate esters, polycyanurates, and silicones.

### Claim 9 (depends on 7)

The method according to claim 7 wherein the second polymeric material supports inclusion into it of additives materials.

### Claim 10 (depends on 1)

The method according to claim 1 wherein the empty volume between the first and the second pattern layers is employed as a mould for the second polymeric material casted in the empty volume between the first and second pattern layers.

### Claim 11

(canceled)

### Claim 12 (depends on 1)

The method according to claim 1 wherein the first polymeric material has mechanical properties different from the second polymeric material and wherein the mechanical properties include at least modulus of elasticity, transparency and appearance.

### Claim at position 13

-20. (canceled)

### Claim 21

A method comprising:
employing a first polymeric material to deposit first and second pattern layers laterally shifted from each other such that laterally shifted pattern layers form between them an empty volume with a variable cross section that varies along the first and second pattern layers;
casting in the empty volume between the first and second pattern layers a second polymeric material to cast a complex shaped 3D object identical in shape to the empty volume between the first and second pattern layers;
applying radiation to cure the second polymeric material and employing at least one of a group of actions consisting of exposure to water or mechanical action to the first and second pattern layers permitting removal of the second polymeric material having the cast complex shaped 3D object identical in shape to the empty volume between the first and second pattern layers; and
exposing the first polymeric material to water to cause it swell and break into beads, and washing out the beads with excess of water to remove the first and second pattern layers from the complex shaped 3D object.

### Claim 22

(canceled)

### Claim 23 (depends on 21)

The method according to claim 21 wherein the mechanical action includes an application of force and pressure to break the first and second pattern layers.

### Claim 24 (depends on 1)

The method according to claim 1, wherein the step of applying radiation includes applying actinic radiation.

### Claim 25 (depends on 1)

The method according to claim 1, wherein the step of applying radiation includes applying ultraviolet radiation.

### Claim 26

(canceled)

### Claim 27 (depends on 21)

The method according to claim 21, wherein the step of applying radiation includes applying actinic radiation.

### Claim 28 (depends on 21)

The method according to claim 21, wherein the step of applying radiation includes applying ultraviolet radiation.

### Claim 29

(canceled)