Process for forming multi-layer flexible molds
OwnerEdwin F. Audsleyinventor
Life of this patent
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Abstract
A process for rapidly forming a flexible mold for finely detailed objects from a radiatively curable molding composition includes coating at least a portion of the surface of a three-dimensional object with a fluid molding composition. The coating is cured by exposing the fluid coating to radiative energy to form an elastic, flexible layer of cured molding composition on the object. The coating and curing steps can be repeated to build up the flexible mold until a predetermined minimum has been attained. The cured molding composition is removed from the object, and is suitable for immediate use as a mold to cast duplicate reproductions of the object.
Claims21
A process for rapidly forming a multilayer flexible mold for finely detailed objects from a radiatively curable molding composition, the process comprising:
- (a) coating at least a portion of the surface of a three-dimensional object with a fluid molding composition, the molding composition being radiatively curable;
- (b) curing the coating to form an elastic, flexible layer of cured molding composition on the three-dimensional object by exposing the fluid coating composition to radiative energy;
- (c) repeating steps (a) and (b) successively until a self-supporting multilayer elastic coating of cured molding composition has been formed on the three-dimensional object, the multilayer coating being sufficiently strong so as to not distort perceptibly when filled with a molding material having a low to moderate density;
- and
- (d) removing the three-dimensional object.
A process for forming a multilayer flexible mold for finely detailed objects from a radiatively curable molding composition, the process comprising:
- (a) coating at least a portion of the surface of a three-dimensional object with at least a predetermined first thickness of a fluid molding composition, the molding composition being radiatively curable;
- (b) curing the coating to form an elastic, flexible layer of cured molding composition on the three-dimensional object by exposing the fluid coating composition to radiative energy for at least a predetermined period;
- (c) repeating steps (a) and (b) successively until an elastic coating of cured molding composition having at least a second predetermined thickness has been formed on the three-dimensional object;
- and
- (d) removing the three-dimensional object;
- the first predetermined thickness being about one millimeter, the predetermined second thickness being about 3-4 millimeters;
- the fluid molding composition comprising at least one crosslinkable oligomer, at least reactive diluent agent, at least one thixotrope, at least one plasticizer for the crosslinkable oligomer, and at least one photoinitiator;
- the at least one oligomer being selected from the group consisting of (meth)acrylate-capped epoxy oligomers, (meth)acrylate-capped polyether oligomers, (meth)acrylate-capped polyester oligomers, (meth)acrylate-capped polybutadiene, (meth)acrylate-capped polychloroprene, (meth)acrylate-capped polyester urethane oligomers, (meth)acrylate-capped polybutadiene oligomers, (meth)acrylate-capped nylon oligomers, (meth)acrylate-capped polysulfide oligomers, (meth)acrylated polybutadiene oligomers, and polychloroprene oligomers.
Dependencies are inferred from the claim text.