Method for Solid Freeform Fabrication

Abstract

The present invention provides methods, processes, and systems for the manufacture of three-dimensional articles made of polymers using 3D printing. A layer of prepolymer is deposited on a build plate to form a powder bed. The deposited powder bed is heated to about 50° C. to about 170° C. Then, a solution of activating agent is printed on the powder bed in a predetermined pattern, and a stimulus is applied converting the prepolymer to the final polymer. After a predetermined period of time, sequential layers are printed to provide the three-dimensional article. The three-dimensional object can be cured to produce the three-dimensional article composed of the final polymers.

1 . The system of  claim 6 , wherein the prepolymer is a polyketone polymer comprising one or more alkene groups or one or more epoxide groups. 
     
     
         2 . The system of  claim 7 , where the stimulus is radiation or heat. 
     
     
         3 . The system of  claim 2 , wherein radiation is ultraviolet radiation, visible radiation, infrared radiation, electron beam radiation, or combinations thereof. 
     
     
         4 . (canceled) 
     
     
         5 . The system of  claim 6 , wherein the photoinitiator is phenylacetophenone (DMPA), azobisisobutyronitrile (AIBN), fluorenone, a phosphine oxide, or combinations thereof. 
     
     
         6 . A system for printing a three-dimensional article, the system comprising:
 a depositing mechanism to depose a powder of prepolymer on a build plate;   a printing mechanism to print a solution of an activating agent and/or a photoinitator at selected locations to form a polymer layer of the three-dimensional article; and   a printing controller to repeat the printing mechanism to print the solution of the activating agent on the polymer layer exposed to a stimulus at a predetermined condition.   
     
     
         7 . The system of  claim 6 , further comprising a stimulating mechanism to expose the solution of the activating agent on the polymer layer to the stimulus