Method for printing 3D parts and support structures with electrophotography-based additive manufacturing
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-035/08
B29C-041/02
B29C-067/00
G03G-013/22
G03G-015/22
B33Y-070/00
B33Y-010/00
B29K-033/00
B29K-025/00
B29K-105/00
B29K-009/06
B29K-033/20
B29K-009/00
출원번호
US-0944483
(2013-07-17)
등록번호
US-9144940
(2015-09-29)
발명자
/ 주소
Martin, Trevor I.
출원인 / 주소
Stratasys, Inc.
대리인 / 주소
Westman, Champlin & Koehler, P.A.
인용정보
피인용 횟수 :
6인용 특허 :
45
초록▼
A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system. The method includes developing a support layer of the support structure from a soluble support material with a first electrophotography engine, and transferring the
A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system. The method includes developing a support layer of the support structure from a soluble support material with a first electrophotography engine, and transferring the developed support layer from the first electrophotography engine to a transfer medium. The method also includes developing a part layer of the three-dimensional part from an ABS part material with a second electrophotography engine, and transferring the developed part layer from the second electrophotography engine to the transfer medium. The method further includes moving the attracted part and support layers to a layer transfusion assembly with the transfer medium, and transfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly.
대표청구항▼
1. A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system, the method comprising: providing a support material compositionally comprising a first charge control agent and a first copolymer having aromatic groups, (meth)ac
1. A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system, the method comprising: providing a support material compositionally comprising a first charge control agent and a first copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups, and anhydride groups;providing a part material compositionally comprising a second charge control agent, and a second copolymer having acrylonitrile units, butadiene units, and aromatic units;developing a support layer of the support structure from the support material with a first electrophotography engine;transferring the developed support layer from the first electrophotography engine to a transfer medium;developing a part layer of the three-dimensional part from the part material with a second electrophotography engine;transferring the developed part layer from the second electrophotography engine to the transfer mediummoving the attracted part and support layers to a layer transfusion assembly with the transfer medium; andtransfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly. 2. The method of claim 1, wherein the support material has a glass transition temperature that is within about 10° C. of a glass transition temperature of the part material. 3. The method of claim 2, wherein the glass transition temperature of the support material is within about 5° C. of the glass transition temperature of the part material. 4. The method of claim 1, wherein the support material has a dynamic viscosity at 200° C. that is within about 10 kilopascal-seconds of a dynamic viscosity at 200° C. for the part material. 5. The method of claim 4, wherein the dynamic viscosity of the support material is within about 5 kilopascal-seconds of the dynamic viscosity at 200° C. for the part material. 6. The method of claim 1, wherein the first copolymer of the support material has an anhydride conversion that is at least 90% of a maximum anhydride conversion for the first copolymer. 7. The method of claim 1, wherein the first copolymer of the support material is polymerized from monomers comprising styrene, n-butyl acrylate, and methacrylic acid. 8. The method of claim 1, wherein the support material and the part material are each provided in a powder fog n independently having a D50 particle size ranging from about 5 micrometers to about 30 micrometers. 9. The support material of claim 8, wherein the powder forms of the support material and the part material also independently have a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 1.40. 10. A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system, the method comprising: providing a charged support material that compositionally comprises a first copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups, and anhydride groups;providing a charged part material that compositionally comprises a second copolymer having acrylonitrile units, butadiene units, and aromatic units, wherein the charged support material has a dynamic viscosity at 200° C. that is within about 10 kilopascal-seconds of a dynamic viscosity at 200° C. for the charged part material;developing a support layer of the charged support structure from the support material;developing a part layer of the three-dimensional part from the charged part material;independently transferring the support layer and the part layer to a transfer medium such that the support layer and the part layer define a combined layer;moving the combined layer to a layer transfusion assembly to previously-printed layers of the three-dimensional part and the support structure; andtransfusing the combined layer to previously-printed layers. 11. The method of claim 10, wherein the dynamic viscosity of the charged support material is within about 5 kilopascal-seconds of the dynamic viscosity at 200° C. for the charged part material. 12. The method of claim 10, wherein the charged support material has a glass transition temperature that is within about 10° C. of a glass transition temperature of the charged part material. 13. The method of claim 10, wherein the charged support material and the charged part material are each provided in a powder form independently having a D50 particle size ranging from about 5 micrometers to about 30 micrometers. 14. The method of claim 13, wherein the powder foul's of the charged support material and the charged part material also independently have a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 1.40. 15. A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system, the method comprising: providing a support material compositionally comprising a first charge control agent and a first copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups and wherein adjacent carboxylic acid groups are converted anhydride groups such that a maximum conversion of carboxylic acid groups to anhydride ranges from about 60% to about 65%, relative to the initial number of carboxylic acid groups in the copolymer group prior to anhydride conversion;providing a part material compositionally comprising a second charge control agent, and a second copolymer having acrylonitrile units, butadiene units, and aromatic units;developing a support layer of the support structure from the support material with a first electrophotography engine;transferring the developed support layer from the first electrophotography engine to a transfer medium;developing a part layer of the three-dimensional part from the part material with a second electrophotography engine;transferring the developed part layer from the second electrophotography engine to the transfer mediummoving the attracted part and support layers to a layer transfusion assembly with the transfer medium; andtransfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly. 16. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is greater than 90% of the maximum conversion. 17. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is greater than 95% of the maximum conversion. 18. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is greater than 95% of the maximum conversion. 19. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is 100% of the maximum conversion. 20. The method of claim 15, wherein the support material has a glass transition temperature that is within about 10° C. of a glass transition temperature of the part material.
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