Systems and methods for using multi-part curable materials

Abstract

Solid freeform fabrication (SFF) systems for producing a three-dimensional object and methods of producing three-dimensional objects are disclosed. The SFF system includes a dispensing system and a curing system. The dispensing system is adapted to dispense a radiation initiator and a build material. The radiation initiator and the build material are stored separately in the dispensing system and are dispensed separately. The curing system cures the radiation initiator and the build material after each has been dispensed.

1 . A solid freeform fabrication system for producing a three-dimensional object, comprising: 
 a dispensing system adapted to dispense a radiation initiator and a build material, the radiation initiator and the build material being stored separately in the dispensing system, the radiation initiator and the build material being dispensed separately; and    a curing system operative to cure the radiation initiator and the build material after each have been dispensed.    
   
   
       2 . The solid freeform fabrication system of  claim 1 , wherein the dispensing system includes at least one ink-jet printhead.  
   
   
       3 . The solid freeform fabrication system of  claim 2 , wherein a first ink-jet printhead includes the radiation initiator in a first compartment and the build material in a second compartment.  
   
   
       4 . The solid freeform fabrication system of  claim 2 , wherein a first ink-jet printhead includes the radiation initiator and a second ink-jet printhead includes the build material.  
   
   
       5 . The solid freeform fabrication system of  claim 1 , wherein the radiation initiator is an ultraviolet (UV) initiator.  
   
   
       6 . The solid freeform fabrication system of  claim 5 , wherein the UV initiator has a viscosity less than 70 centipoise at a temperature below about 200° C.  
   
   
       7 . The solid freeform fabrication system of  claim 5 , wherein the UV initiator has a viscosity less than 20 centipoise at a temperature below about 120° C.  
   
   
       8 . The solid freeform fabrication system of  claim 5 , wherein the UV initiator is selected from a free radical initiator, a cationic initiator, and combinations thereof.  
   
   
       9 . The solid freeform fabrication system of  claim 5 , wherein the UV initiator includes a colorant.  
   
   
       10 . The solid freeform fabrication system of  claim 1 , wherein the build material has a viscosity less than 70 centipoise at a temperature below about 200° C.  
   
   
       11 . The solid freeform fabrication system of  claim 1 , wherein the build material has a viscosity less than 20 centipoise at a temperature below about 120° C.  
   
   
       12 . The solid freeform fabrication system of  claim 1 , wherein the build material is selected from acrylic compounds, compounds having one or more epoxy substituents, one or more vinyl ether substituents, vinylcaprolactam, vinylpyrrolidone, urethanes, and combinations thereof.  
   
   
       13 . The solid freeform fabrication system of  claim 1 , wherein the build material includes a dye.  
   
   
       14 . The solid freeform fabrication system of  claim 1 , further comprising a computer control system operative to control the dispensing system and the curing system.  
   
   
       15 . The solid freeform fabrication system of  claim 1 , wherein the curing system comprises an ultraviolet curing system.  
   
   
       16 . A method of producing a three-dimensional object, comprising the steps of: 
 providing a radiation initiator;    providing a build material, wherein the radiation initiator and the build material are separated from each other;    dispensing the radiation initiator and the build material onto a build platform independently, wherein the radiation initiator and the build material are commingled to form a multi-part radiation curable material; and    curing the multi-part radiation curable material to produce the three-dimensional object.    
   
   
       17 . The method of producing a three-dimensional object of  claim 16 , further comprising: 
 heating the build material to a temperature of about 40 to 200° C.    
   
   
       18 . The method of producing a three-dimensional object of  claim 16 , further comprising: 
 heating the build material to a temperature of about 70 to 120° C.    
   
   
       19 . The method of producing a three-dimensional object of  claim 16 , wherein dispensing includes: 
 dispensing a layer of the build material; and    dispensing a layer of the radiation initiator onto the layer of the build material thereby forming the multi-part radiation curable material.    
   
   
       20 . The method of producing a three-dimensional object of  claim 16 , wherein dispensing includes: 
 dispensing a layer of the radiation initiator; and    dispensing a layer of the build material onto the layer of radiation initiator thereby forming the multi-part radiation curable material.    
   
   
       21 . The method of producing a three-dimensional object of  claim 16 , wherein dispensing includes: 
 dispensing the build material in a spaced manner; and    dispensing the radiation initiator within the spaces between the build material, wherein the build material and the radiation initiator form a layer of commingled build material and radiation initiator thereby forming the multi-part radiation curable material.    
   
   
       22 . The method of producing a three-dimensional object of  claim 16 , further comprising: 
 mixing the radiation initiator and the build material using ultrasonic energy.    
   
   
       23 . The method of producing a three-dimensional object of  claim 16 , wherein dispensing the UV initiator and the build material is performed sequentially.  
   
   
       24 . The method of producing a three-dimensional object of  claim 16 , wherein dispensing the radiation initiator and the build material is performed simultaneously.  
   
   
       25 . The method of producing a three-dimensional object of  claim 16 , further comprising means for controlling the temperature of the build platform.  
   
   
       26 . The method of producing a three-dimensional object of  claim 16 , wherein the radiation initiator is an ultraviolet initiator.  
   
   
       27 . The method of producing a three-dimensional object of  claim 16 , wherein dispensing the radiation initiator and the build material further comprises: 
 dispensing the radiation initiator from a first ink-jet printhead and dispensingthe build material from a second ink-jet printhead.