# US 9,750,914 B2 · Methods for fabricating objects using investment molding techniques > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,750,914 B2 - Document ID: US9750914B2 - Status: Granted - Kind: B2 - Application number: 14/173,549 - Filed: 2014-02-05 - Published: 2015-02-05 - Granted: 2017-09-05 - Earliest claimed: 2013-08-01 - Assignees: MetaMason, Inc. - Applicants: MetaMason, Inc. - Inventors: Leslie Oliver Karpas; Aaron M. Ryan - Web page: https://patentgrep.com/patent/US9750914B2 ## CPC - B29C 64/386: Data acquisition or data processing for additive manufacturing - A61M 16/0605: {Means for improving the adaptation of the mask to the patient} - A61M 16/0666: {Nasal cannulas or tubing (devices for improving normal breathing through the nose A61F5/08; nose filters A62B23/06; outside holding devices A61M25/02)} - A61M 16/0683: {Holding devices therefor} - A61M 16/0816: {Joints or connectors} - A61M 16/0875: {Connecting tubes} - B29C 33/52: soluble or fusible {(in particular used in injection moulding B29C45/4457)} - B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material - B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof - B33Y 10/00: Processes of additive manufacturing - B33Y 50/02: for controlling or regulating additive manufacturing processes - B33Y 80/00: Products made by additive manufacturing - G06F 30/00: Computer-aided design [CAD] - G06T 17/00: Three-dimensional [3D] modelling for computer graphics - G06V 40/171: {Local features and components; Facial parts (eye characteristics G06V40/18); Occluding parts, e.g. glasses; Geometrical relationships} - G06V 40/193: {Preprocessing; Feature extraction} - A61M 2016/0661: {with customised shape} - A61M 2207/00: Methods of manufacture, assembly or production - B29K 2101/12: Thermoplastic materials - B29K 2995/0059: Degradable - B29K 2995/0062: water-soluble - 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) - A61M: DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY (introducing media into or onto the bodies of animals A61D7/00; means for inserting tampons A61F13/26; devices for administering food or medicines orally A61J; containers for collecting, storing or administering blood or medical fluids A61J1/05); DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY (surgery A61B; chemical aspects of surgical articles A61L); DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR {(Electrotherapy, e.g. producing anaesthesia by the use of alternating or intermittent currents A61N1/36021)} - 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 - G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N) - G06T: IMAGE DATA PROCESSING OR GENERATION, IN GENERAL - G06V: IMAGE OR VIDEO RECOGNITION OR UNDERSTANDING - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract Systems and methods in accordance with embodiments of the invention fabricate objects using investment molding techniques. In one embodiment, a method of fabricating an object includes: fabricating a subassembly including a plurality of volumes; where each volume is defined by the homogenous presence or absence of a material; where fabricating the subassembly includes using an additive manufacturing process; where at least one of the plurality of volumes defines a shape that is to exist in the object to be fabricated; where at least a first of the plurality of volumes includes a first dissolvable material; dissolving the first dissolvable material; where the dissolution of the first dissolvable material does not dissolve at least one other material within the subassembly; forming at least one cavity within the subassembly; and introducing an additive material into the at least one cavity. ## Claims ### Claim 1 A method of fabricating an object comprising: fabricating a subassembly comprising a plurality of volumes; wherein each volume is defined by the homogenous presence or absence of a material; wherein fabricating the subassembly comprises using an additive manufacturing process; wherein at least one of the plurality of volumes defines a shape that is to exist in the object to be fabricated; wherein at least a first of the plurality of volumes comprises a first dissolvable material; forming a first cavity within the subassembly; wherein the first cavity is adjacent to the first dissolvable material; introducing a first additive material into the first cavity; dissolving the first dissolvable material subsequent to the introduction of the first additive material; wherein the dissolution of the first dissolvable material does not dissolve at least one other material within the subassembly; wherein the dissolution of the first dissolvable material results in the creation of a second cavity that is adjacent to the introduced first additive material; and introducing a second additive material into the second cavity that is different from the first additive material. ### Claim 2 (depends on 1) The method of claim 1, wherein the subassembly is additively manufactured to include at least one cavity. ### Claim 3 (depends on 1) The method of claim 1, wherein the first cavity is formed by dissolving at least one of the plurality of volumes. ### Claim 4 (depends on 3) The method of claim 3, wherein the subassembly comprises a volume that is defined by the homogenous presence of a material, where the material acts to support the subassembly when the first cavity is formed and when the first additive material is introduced into the first cavity. ### Claim 5 (depends on 4) The method of claim 4, further comprising removing the material that acts to support the subassembly when the first cavity is formed and when the first additive material is introduced into the first cavity. ### Claim 6 (depends on 5) The method of claim 5, wherein the removal of the material that acts to support the subassembly when the first cavity is formed and when the first additive material is introduced into the first cavity is achieved mechanically. ### Claim 7 (depends on 5) The method of claim 5, wherein the removal of the material that acts to support the subassembly when the first cavity is formed and when the first additive material is introduced into the first cavity is achieved by dissolving the material. ### Claim 8 (depends on 3) The method of claim 3, wherein the first dissolvable material is one of: prolyvinyl alcohol (PVA), high impact polystyrene (HIPS), polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), nylon, polycarbonate, glucose, glucose gelatin, polyethylene terephthalate (PET), polycarprolactone (PCL), low-density polyethylene (LDPE), high density polyethylene (HDPE), polymethylpentene (PMP), polypropylene (PP), polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), and mixtures thereof. ### Claim 9 (depends on 8) The method of claim 8, wherein dissolving the first dissolvable material comprises subjecting the first dissolvable material to a respective solvent. ### Claim 10 (depends on 9) The method of claim 9, wherein the solvent is one of: water, terpene, limonine, sodium hydroxide, acetone, acetic acid, dichloromethane, respective enzymes, acetaldehyde, acetic anhydride, acetone, hydrofluoric acid, trifluoroacetic acid, dilute acetic acid (50%), hydrochloric acid (37%), nitric acid, sulfuric acid, ethyl alcohol, isobutyl alcohol, methyl alcohol, n-butyl alcohol propyl alcohol, ammonium hydroxide, aniline, aqua regia, benzaldehyde, benzene, carbon tetrachloride, caustic soda (NaOH), chlorobenzene, chloroform, cyclohexane, esters, ether, diethyl ether, isopropyl ether, methyl ethyl, hexane, hydrazine, hydrogen peroxide, methylene chloride, petroleum ether, phenol, sodium hydroxide, tetrahydrofuran, toluene, trichloroethylene, trimethylpentane, xylene, and mixtures thereof. ### Claim 11 (depends on 1) The method of claim 1, wherein: a second volume defines a body portion and a sprue portion that extends from the body portion to the external surface of the subassembly and thereby defines the first cavity; and the introduction of the first additive material into the first cavity comprises introducing the additive material into the body portion through the sprue portion. ### Claim 12 (depends on 11) The method of claim 11, wherein: the first volume and the second volume are defined such that when the first additive material is introduced into the second volume beyond a threshold extent, and the additive material achieves a solid state, the additive material provides sufficient structural support to maintain the spatial relationship between the first volume and the second volume when the first dissolvable material is dissolved. ### Claim 13 (depends on 12) The method of claim 12, wherein the first additive material is introduced into the second volume to the extent that the additive material conforms to the shape of at least a part of the sprue portion, and upon solidification, thereby provides sufficient structural support to maintain the spatial relationship between the first volume and the second volume when the first dissolvable material is dissolved. ### Claim 14 (depends on 11) The method of claim 11, wherein the subassembly comprises a volume that is defined by the presence of a material, where the material acts to support the subassembly when the first dissolvable material is dissolved and when the first additive material is introduced into the second volume. ### Claim 15 (depends on 14) The method of claim 14, further comprising removing the material that acts to support the subassembly when the first dissolvable material is dissolved and when the first additive material is introduced into the second volume. ### Claim 16 (depends on 15) The method of claim 15, wherein the removal of the material that acts to support the subassembly when the first dissolvable material is dissolved and when the first additive material is introduced into the second volume is achieved mechanically. ### Claim 17 (depends on 15) The method of claim 15, wherein the removal of the material that acts to support the subassembly when the first dissolvable material is dissolved and when the first additive material is introduced into the second volume is achieved by dissolving the material. ### Claim 18 (depends on 11) The method of claim 11, wherein the first dissolvable material is one of: prolyvinyl alcohol (PVA), high impact polystyrene (HIPS), polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), nylon, polycarbonate, glucose, glucose gelatin, polyethylene terephthalate (PET), polycarprolactone (PCL), low-density polyethylene (LDPE), high density polyethylene (HDPE), polymethylpentene (PMP), polypropylene (PP), polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), and mixtures thereof. ### Claim 19 (depends on 18) The method of claim 18, wherein dissolving the first dissolvable material comprises subjecting the first dissolvable material to a respective solvent. ### Claim 20 (depends on 19) The method of claim 19, wherein the solvent is one of: water, terpene, limonine, sodium hydroxide, acetone, acetic acid, dichloromethane, respective enzymes, acetaldehyde, acetic anhydride, acetone, hydrofluoric acid, trifluoroacetic acid, dilute acetic acid (50%), hydrochloric acid (37%), nitric acid, sulfuric acid, ethyl alcohol, isobutyl alcohol, methyl alcohol, n-butyl alcohol propyl alcohol, ammonium hydroxide, aniline, aqua regia, benzaldehyde, benzene, carbon tetrachloride, caustic soda (NaOH), chlorobenzene, chloroform, cyclohexane, esters, ether, diethyl ether, isopropyl ether, methyl ethyl, hexane, hydrazine, hydrogen peroxide, methylene chloride, petroleum ether, phenol, sodium hydroxide, tetrahydrofuran, toluene, trichloroethylene, trimethylpentane, xylene, and mixtures thereof. ### Claim 21 (depends on 1) The method of claim 1, wherein the volume that defines a shape that is to exist in the object to be fabricated is occupied by solid material in the fabricated object.