Three-dimensional structured printing
AssigneeHuntsman Advanced Materials Americas LLC
InventorsRanjana Patel, Richard J. Peace, Yong Zhao, Jeremy Powell, Michael Rhodes
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Abstract
A process for forming a three-dimensional article in sequential layers in accordance with a digital model of the article. The process comprises the steps of defining a layer of powder material, applying a liquid reagent to the powder layer in a pattern corresponding to the digital model, and repeating these steps to form successive layers. The powder comprises a first reactive component and the liquid includes a second active component capable of reacting with the first reactive component so that the article is built up in layers.
Claims64
A process for forming a three-dimensional article in sequential cross-sectional layers in accordance with a model of the article, the process comprising the steps of:
- defining a layer of powder material;
- applying a liquid reagent to the powder layer in a pattern corresponding to a respective cross-sectional layer of the model;
- and
- repeating these steps to form successive layers;
- wherein the powder comprises a first reactive component selected from an organic or organometallic polymer, oligomer or monomer and the liquid reagent includes a second active component comprising an oxetane, the second active component causing a polymerization reaction to take place in said layer by chemically reacting with said first reactive component within the powder to form a new chemical component, and thereby to form substantially void-free regions in the article where the liquid reagent has been applied to the powder material and wherein the article which is formed has a tensile strength of greater than about 25 MPa.
A process for forming sequential cross-sectional layers of a three-dimensional article comprising:
- defining a layer of powder material;
- through a plurality of nozzles, applying a liquid reagent to the powder layer in a pattern corresponding to a respective cross-sectional layer of the model;
- repeating these steps to form successive layers;
- wherein the powder comprises a first reactive component selected from an organic or organometallic polymer, oligomer or monomer and the liquid reagent includes a second active component comprising an oxetane, the second active component causing a polymerization reaction to take place in said layer by chemically reacting with said first reactive component within the powder to form a new chemical component, and thereby to form substantially void-free regions of high strength in the article where the liquid reagent has been applied to the powder material and wherein the article which is formed has a tensile strength of greater than about 25 MPa.
A process for forming a substantially void-free three-dimensional article in sequential cross-sectional layers in accordance with a model of the article, the process comprising the steps of:
- defining a layer of powder material;
- via a plurality of micro-fine nozzles, jetting a liquid reagent onto the powder layer in a pattern corresponding to a respective cross-sectional layer of the model, said liquid reagent dissolving the powder material which comes into contact with it;
- repeating these steps to form successive layers;
- wherein the powder comprises a first reactive component selected from an organic or organometallic polymer, oligomer or monomer and the liquid reagent includes a second active component comprising an oxetane, the second active component causing a polymerization reaction to take place in said layer by chemically reacting with said first reactive component within the powder to form a new chemical component, and thereby forming substantially void-free regions of high strength in the article where the liquid reagent has been jetted on the powder layer and wherein the article which is formed has a tensile strength of greater than about 25 MPa.
Dependencies are inferred from the claim text.