Methods and systems for fabricating three-dimensional objects by additive manufacturing
OwnerVipul Gupta, Ahmad Reza Norouziinventors
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Abstract
A hybrid Direct Ink Writing and photo-curing system and methods of using same, including a method for fabricating a three-dimensional object layer-by-layer upon a work surface using one or more photocurable inks, the work surface configured to be moveable relative to an ink deposition arrangement and a light source, the method comprising forming a layer of the three-dimensional object, said forming of a layer comprising: depositing photocurable ink; and selectively exposing the deposited ink to the light source, to thereby cure at least a portion of the deposited ink; the cured portion forming at least part of a layer of the three-dimensional object.
Claims32
A method for fabricating a three-dimensional object layer-by-layer upon a work surface using two or more photocurable inks, the work surface configured to be moveable relative to an ink deposition arrangement and a light source, the method comprising forming a layer of the three-dimensional object, said forming of a layer comprising:
- depositing a first photocurable ink;
- selectively exposing the deposited first ink to the light source, to thereby cure at least a portion of the deposited first ink;
- depositing a second photocurable ink;
- and
- selectively exposing the deposited second ink to the light source, to thereby cure at least a portion of the deposited second ink;
- wherein the cured portions of the first ink and the second ink form at least part of a layer of the three-dimensional object.
A method according to any preceding claim, wherein the deposition arrangement is positioned at a first height above the work surface during deposition of the first ink, and wherein the deposition arrangement is positioned at a second height above the work surface during deposition of the second ink.
A method according to any preceding claim, wherein the ink deposition arrangement comprises two or more ink dispensers, each of the two or more ink dispensers configured for dispensing a respective ink.
A method according to any preceding claim, wherein the two or more photocurable inks each comprise a precursor of a material for forming a polymer, and forming said polymer comprises one or more of:
- reacting a reactive thiol group of the ink with an ene compound of the ink, comprising one or more reactive ene groups, under conditions that promote a thiol-ene reaction;
- reacting a reactive thiol group of the ink with an yne compound of the ink, comprising one or more reactive yne groups, under conditions that promote a thiol-yne reaction;
- reacting a reactive thiol group of the ink with an acrylate compound of the ink, comprising one or more reactive acrylate groups, under conditions that promote a thiol-acrylate reaction.
A method according to any preceding claim, wherein the two or more photocurable inks each comprise one or more organosilicon-based monomers.
A method according to any preceding claim, wherein one or more of the photocurable inks comprise ceramic particles.
A method according to any preceding claim, wherein one or more of the photocurable inks comprise one or more additives selected from the group consisting of a free-radical scavenger, a photoblocker and a photoinitiator.
A method according to any preceding claim, wherein the one or more inks have a viscosity in the range of about 0.1 Pa·s to 1000 Pa·s.
A method according to any preceding claim, wherein selectively exposing said deposited ink to said light source comprises generating a pattern of photocuring light, and projecting said pattern upon at least a portion of said deposited inks.
A method according any preceding claim, wherein exposure to said light source is carried out for an exposure time of between 1 millisecond to 1 hour.
A method according to any preceding claim, wherein the light source produces a photocuring light having a wavelength within the UV or visible spectrum.
A method for fabricating a three-dimensional object layer-by-layer upon a work surface using one or more photocurable inks, the work surface configured to be moveable relative to an ink deposition arrangement and a light source, the method comprising, for at least one layer of the three-dimensional object, forming said at least one layer such that said forming comprises:
- depositing a photocurable ink to a first thickness, determined in a direction normal to a plane of the work surface;
- and
- selectively exposing the deposited ink to the light source, to thereby cure at least a portion of the deposited first ink;
- wherein the selective exposure of the deposited ink to the light source is configured such that said cured portion extends to a cured thickness, determined in a direction normal to a plane of the work surface, the cured thickness being less than or substantially equal to the deposited thickness.
A method for fabricating a three-dimensional object layer-by-layer upon a work surface using one or more photocurable inks, the work surface configured to be moveable relative to an ink deposition arrangement and a light source, the method comprising forming a layer of the three-dimensional object, said forming of a layer comprising:
- depositing photocurable ink;
- and
- selectively exposing the deposited ink to the light source, to thereby cure at least a portion of the deposited ink;
- the cured portion forming at least part of a layer of the three-dimensional object.
A system for fabricating a three-dimensional object layer-by-layer using one or more photocurable inks, said system comprising:
- a work surface upon which the three-dimensional object is fabricated;
- an ink deposition arrangement configured for spatially controlled depositing of layers comprising one or more photocurable inks, each layer being in an initial ink deposition;
- and
- a light source configured for selectively exposing each initial ink deposition to light so that at least part of said initial ink deposition is photocured to provide a consolidated layer of the three-dimensional object;
- wherein the relative positioning of the work surface to the ink deposition arrangement and the light source is variable.
Dependencies are inferred from the claim text.