Additive manufacturing in gel-supported environment

Abstract

To provide additive manufacturing techniques that can be used to form three-dimensional objects.SOLUTION: A method of producing a three-dimensional object is described. A nozzle 150 is placed in a gel 170 in a gel container 160. The nozzle is repositioned in the gel while depositing the solidified material exiting the nozzle. The gel supports the solidified material at the position where the solidified material was deposited. The solidified material solidifies to form a solid object, the three-dimensional object 180c.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] This application is a continuation of U.S. Provisional Patent Application No. 62 / 481,358, filed April 4, 2017. No. 6,313,935, filed on Oct. 13, 2003, which is hereby incorporated by reference in its entirety. . [Background technology]

[0002] Traditional manufacturing typically involves molding parts or other components that have a fixed shape, which These individual components are often assembled into more complex structures. However, they are often expensive and can require a lot of manual labor. The molds used in this process are expensive to manufacture and the dimensions and shapes of the resulting molded products cannot be changed. do not have.

[0003] Additive manufacturing is the process of creating three-dimensional objects by adding material layer by layer. A general term for a technology that creates objects. Stereolithography (SLA) is a process that exposes a polymer to UV light. It is an additive manufacturing technology that uses selective photopolymerization.

[0004] Selective laser sintering (SLS), direct metal laser sintering (DMLS), and laser Selective Laser Melting (SLM) is an additive manufacturing technique in which a thin layer of powder is distributed onto a substrate. In SLM and DMLS, the powder is selectively sintered by a laser. Unlike SLA, which is typically used for polymers, SL S, DMLS and SLS can be used on metals.

[0005] Fused Deposition Modeling (FDM) is a method of fabricating parts using fused filament fabrication. Sometimes referred to as FFF (Fiber-Fiber-Filled), this process selectively deposits molten material along a predefined path, layer by layer. By applying pressure to the object, an object is formed.

[0006] One problem with existing technology is that it is too slow. Another problem with existing technology is that it is too slow. The problem is that for the manufacture of complex shapes (such as unsupported overhangs), the The problem is that it may be necessary to create a support structure for the This often increases the cost of designing parts and increases the processing time required to create the parts. In addition, some or all of the support structure is discarded, making it difficult to make the part. The cost of materials to manufacture the product increases. Summary of the Invention [Problem to be solved by the invention]

[0007] The methods described herein relate to additive manufacturing techniques that can be used to form three-dimensional objects. do. [Means for solving the problem]

[0008] A method for producing a three-dimensional object is described below. The method comprises the steps of: placing a nozzle in the gel while depositing solidified material exiting the nozzle; and repositioning the nozzle within the gel to cause the gel to transfer the solidification material to the solidification material. and supporting the material in a deposited position; and solidifying the solidified material to form a three-dimensional object. forming a solid body.

[0009] Depositing the solidified material exiting the nozzle may further include, for example, depositing one or more pipes. The pressure applied to the stone is changed to push out the solidified material, thereby The rate at which the gel is deposited may be varied. Varying the position of the nozzle in the nozzle chamber further comprises varying the position of the nozzle at a varying rate. This may include changing the position of the

[0010] The nozzle may be mounted on a multi-axis machine. including operating one or more axes of the multi-axis machine to which the nozzle is attached. The changing of the position of the nozzle in the gel may include changing the position of the gel container. It may include changing.

[0011] and solidifying the solidifying material includes exposing the solidifying material to light or heat. Solidifying the solidification material may include cooling the solidification material. Solidifying the solidified material includes depositing the solidified material exiting the nozzle while: The method may include exposing the solidified material to light.

[0012] The solidification material may be a polymer, rubber, pulp, foam, metal, concrete, or epoxy. The rubber may be a silicone rubber.

[0013] The hardness of the solidified material ranges from about Shore 00-10 to about Shore 90D upon solidification. This is also fine.

[0014] The solidified material may be foam. The solidified foam may have a density of about 3 lb / ft 3 (pounds / foot cubed) ~ approx. 30 lb / ft 3 may be also possible.

[0015] The gel may be a suspension. The gel may include carbomer or polyacrylic acid. The viscosity of the gel may be 20,000 cP (centipoise) to about 50,000 cP. It's fine.

[0016] The nozzle may have a circular, rectangular, square, diamond, V-shaped, U-shaped, or C-shaped tip ( The solidified material may be deposited on the tip of the nozzle.

[0017] The solidification material may include two compounds that are copolymerized. The step of forming the nozzle may include copolymerizing the two compounds. and, further comprising: a nozzle for depositing the two compounds; The mixing section mixes the above components.

[0018] The varying the position of the nozzle, at least temporarily, in three to eight axial directions simultaneously. and changing the position of the nozzle in the gel. The repositioning at least temporarily repositions the nanoparticles in the gel in five to eight axes simultaneously. Varying the position of the nozzle may include varying the position of a nozzle. and varying the position of the nozzle within the gel in three to six axes simultaneously, at least temporarily. The varying the position of the nozzle includes, at least temporarily, rotating the nozzle in six axes simultaneously. and varying the position of the nozzle in the gel.

[0019] Varying the position of the nozzle may allow the nozzle to move on, around, or around other objects in the gel. and varying the position of the nozzle to deposit a solidified material therein. stomach.

[0020] The nozzle may be a first nozzle and the solidification material may be a first solidification material. The solid may be a first solid. positioning a second nozzle in the gel; and depositing a second solidified material exiting the second nozzle. and changing the position of the second nozzle in the gel while the gel is a second solidification material is supported at the position where the second solidification material is deposited, Depositing the materials is performed such that the first and second materials are in deposited contact. allowing the second solidification material to solidify to form a second solid object, and wherein the first and second solid bodies are joined together as the three-dimensional object. The first and second nozzles may have tips with different shapes. The curing material may be a different material.

[0021] In the following, a device for manufacturing three-dimensional objects is described. The device is mounted on a multi-axis machine. a nozzle having a gel container, a means for extruding a solidifying material from the nozzle, good.

[0022] The apparatus may be configured as described herein to perform the methods described herein. Cut.

[0023] The method described herein offers many advantages. In particular, the method is fast. Compared to additive manufacturing methods (such as FDM and SLM), the additive manufacturing methods described here Printing in a gel suspension in the disclosed embodiments of the system and method is complex. It is much faster and more efficient when printing parts with shapes (such as the shape shown in FIG. 4). In some cases, the method can be orders of magnitude faster than existing methods. This can be over 300 times faster. Since there is no need to deposit support structures, the fabricated object can be fabricated without any post-processing. Processing is substantially reduced. For example, post-processing can simply involve washing the object in water. There is no need to manually cut or otherwise remove support structures. The method can also be used to produce larger objects. The size of the gel container is , is the only factor limiting the size of objects that can be manufactured.

[0024] It is possible to increase the speed and size compared to the known art, and The objects produced are of high quality. The solidification materials that can be used in the methods described herein include Examples of suitable materials include industrial grade materials. For example, the methods described herein can be used with silicones. It can be used to create objects using rubber that is not silicone in other ways. The use of elastomers may be required. The method also involves making materials from foams. Additionally, the method can be used to make materials from hard polymers. It can also be used to fabricate ceramics, but other methods may require sintering of the powder. The methods described herein may result in layer-by-layer deposition of the resulting object, which may have poor mechanical properties. Since no deposition is required, the object formed has a uniform cross-section. It does not have a laminate that can be mechanically inferior to the [Brief description of the drawings]

[0025] The foregoing description is in accordance with the following more particular description of exemplary embodiments that are illustrated in the accompanying drawings. In these figures, identical parts are provided with identical reference numerals. The drawings are not necessarily to scale, emphasis instead being placed on illustrating the embodiments. is. [Figure 1] FIG. 1 is a diagram of a three-axis gantry machine with a two-component mixed deposition system for printing three-dimensional parts in a gel suspension. [Diagram 2] FIG. 1 is a diagram of a six-axis robotic arm with a two-component mixing deposition system for printing three-dimensional parts in a gel suspension. [Diagram 3] FIG. 1 is a diagram of a deposition system using a two-component solidification material where the solidification material flows from a mixing tip in a pneumatically controlled manner so that it is thoroughly mixed and forced out of the nozzle. [Figure 4] A comparison of different printing methods used on the same diagonally-shaped part. [Diagram 5] FIG. 1 illustrates various nozzle shapes, sizes and the resulting print paths. [Figure 6] A diagram of a large vat of gel suspending medium that prints a life-size chair suspended in 3D space. [Figure 7] FIG. 13 shows the printed portion of the chair on and / or around a metal frame inserted into a large tank. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] In the following, exemplary embodiments are described.

[0027] As used herein, the term "gel" refers to a colloid in which particles are dispersed in a liquid medium. Typically, the dispersed particles are crosslinked. The gel is thixotropic. Most gels are primarily liquid in terms of weight, but the liquid may be The three-dimensional cross-linked network of the polymer exhibits solid-like material properties.

[0028] The methods described herein relate to additive manufacturing methods in a gel suspension environment. Typically, the gel is The solidifying material can be in a molten or liquid state and is placed in a nozzle and tool path. Deposition occurs via.

[0029] In some embodiments, a multi-axis machine is used to control the path of a nozzle moving through the gel. An example of a multi-axis machine is a gantry-type system. and industrial robot arms. In general, various types of multi-axis machines and robots Gantry-style machines usually have three moving arms. It provides the axes of motion (i.e. x, y and z axes). For example, a 5-axis robot arm has 5 separate rotation axes. A 6-axis robot arm can rotate on six separate axes of rotation. In addition to the rotating shaft, the robot arm can be mounted on a straight rail or gantry machine. It is also possible to provide a linear axis of motion. Axial robot arms can operate in seven axes. Another example is a gantry machine mounted The 6-axis robot arm can move in 7, 8 or 9 axes depending on the specific motion of this gantry machine. It is possible to make

[0030] In addition to the axes of motion provided by the multi-axis machine, the container containing the gel is also moved. For example, the gel container can be placed in a multi-axis gantry machine, and the multi-axis gantry The nozzle is mounted on a multi-axis machine with three separate axes of motion, The gel container can be moved. The gel container can also be moved around a rotation axis. It is also possible.

[0031] In some embodiments, the gel container moves in one axis and the nozzle moves in two axes. In some embodiments, the nozzle is stationary and the tank is two-axis or three-axis. In some embodiments, the tank is controlled by a gantry machine.

[0032] In some embodiments, the nozzle is a winch robot, also known as a cable robot. In these embodiments, a plurality of cables are connected to the nozzle. Control the movement in x, y and z directions.

[0033] The combination of these components allows for extremely fast printing with a variety of materials. For example, a molten polymer may exit the nozzle, deposit, and solidify. The polymerization may include polymerization, which may be photopolymerization. In other embodiments, the polymer may be added. Can be heated to accelerate the polymerization reaction rate. Chemically cured, light cured, or air / water cured. Print plastics, rubber, foams and other liquids at large-scales The system can be used in a wide variety of applications, limited only by the size of the vessel or robotic device. It is possible to control the flow rate, size, direction and cross-sectional shape of complex triplet pumps. 2D tool paths can be generated and printed in any orientation and direction in 3D space. It is.

[0034] Existing additive manufacturing methods have limitations in speed and size compared to other industrial manufacturing methods. The method described herein is different from other three-dimensional printing methods in that it has been used in a variety of applications, including in the manufacturing of printed materials, which has been more limited in industrial applications. This eliminates the need for support material and reduces printing speed while waiting for the material to solidify. In addition, the use of gel suspensions can improve printing speed. In addition, other additive manufacturing methods (e.g., FD) take too long to print large structures. M, inkjet printing using liquid binders and powders (e.g., from ZCorp (sold and achieved by 3D systems), SLA, SLS, and Polyjet Printing (e.g. CONNEX printers sold by Stratasys Ltd) )), the object is not built up layer by layer, which also increases the speed of production. Or parts can be printed in three-dimensional space.

[0035] Figure 4 shows a comparison of different additive manufacturing printing methods used on the same braced part. In FDM printing, the part is cut into horizontal slices, with overhangs supporting the In SLA printing, the part is printed with transversely sliced ​​support areas. It is sliced ​​horizontally and has small vertical supports to support the overhanging parts. In powder-based systems (e.g., SLS or ZCorp), The part is then sliced ​​transversely, with the surrounding powder supporting the overhanging portion. In the method of the gel-supported environment described in , the part is formed without being sliced ​​laterally. The components are printed immediately in their orientation, effectively improving the printing speed and structural continuity of the parts. , the surrounding gel acts as a support material.

[0036] Since no support structure is required, post-processing time is also significantly reduced. The support structures were manually removed or dissolved. In the present method, the printing time was Limited only by the speed and hardening time of the deposited solidified material (seconds to hours depending on the composition) Limited.

[0037] The scale of printing is variable. By using smaller nozzle tips, Larger nozzles allow for the creation of extremely small structures with fine features. By using, larger structures with larger features can be formed.

[0038] FIG. 1 is a diagram of a three-axis gantry machine 100 for use with two-component materials. 10 is mounted on a gantry so as to be operable in the x-axis, y-axis and z-axis as shown. In this particular embodiment, the air pressure control system is The pneumatic deposition can be performed by the pneumatic control system including the piston 126a and 126b (see FIG. 3) is provided with a chamber 120 for applying a force to the two different materials. Two chambers 130a and 130b are provided for containing the materials. The mixture is mixed at the confluence point 140 and exits through a nozzle 150 for deposition. As the arm 110 moves, the nozzle 150 is inserted into the gel. and the two materials are forced out of chambers 130a and 130b into the gel. A three-dimensional object (printed part) 180a is formed by printing the two-component material. 1. The other parts are substantially the same as those in FIG.

[0039] FIG. 3 shows a deposition system for a two-component material with pneumatically controlled flow through a mixing tip. FIG. 1 shows the air entering through tube 124 and flowing through pressure regulator 122. The air enters chamber 120. This causes the air to enter pistons 126a and 126b. A downward force is applied to push the material out of chambers 130a and 130b, respectively. Material (eg, liquid) 180 b is forced out of nozzle tip 150 .

[0040] Instead of the pneumatic deposition shown in FIG. 3, a motorized screw deposition system can also be used. For example, a motor can be used to apply a downward force to pistons 126a and 126b. can.

[0041] FIG. 6 illustrates the use of the invention described herein in forming a chair 180c.

[0042] 1. Deposition of solidified material 1.1.Materials The methods described herein use a deposition system to deposit solidifying materials of various amounts and viscosities. The method provides the advantages of easy liquid material flow / deposition, faster printing speed, and industrial applicability. This allows the use of high-grade materials, which is a distinct advantage compared to other additive manufacturing methods. In some embodiments, the solidification material is a single compound. The solidifying material is two different compounds that copolymerize.

[0043] To date, various plastics, which are one-part or two-part air-curing or chemically curing materials, have been developed. Adhesive binders, foams, and rubbers have been tested. Most other methods By using powder materials with dies, selective sintering of powders, UV-curable polymers, or hot end filament extrusion, This inherently limits the possible materials and the final material properties of the printed structures. The method described in the document applies to polyurethane (PU) rubber, foams and plastics, resins, silicones, etc. Cone, biomaterials, liquid wood pulp, concrete, liquid metal or any other solidifying material It can be used to print with industrial grade materials such as The possibilities for use are greatly expanded.

[0044] Examples of foams include urethane and silicone foam. As used herein, foam refers to a material that has pockets of gas trapped in a liquid or solid. The foam is typically deposited in liquid form and then solidifies.

[0045] Examples of plastics include urethane, acrylic and polymethyl methacrylate. Chemically cured plastics, radiation cured plastics and moisture cured plastics Examples of plastics that can be used include:

[0046] Examples of resins include epoxy resins, phenol-formaldehyde resins, anaerobic resins, and cyanoacrylates.

[0047] Examples of silicones include addition and condensation cured silicone rubbers (hardness varies depending on hardness when solidified). The range of Shore A is from 00-10 to 60A.

[0048] Examples of urethane rubber include materials with hardness ranging from Shore 10A to Shore 90D. can be done.

[0049] Examples of biomaterials include bacteria, antibodies, lignin, growth media, yeast, cell maturation, and cellular matrices, eukaryotic cells, non-eukaryotic cells, fungal medium ), and seed / plant growth.

[0050] Examples of liquid wood pulps include cellulose, lignin, and natural and synthetic fibers. Other paper fiber mixes include those containing both cellulose fiber and cellulose fibre.

[0051] Examples of concrete include Portland cement, or concrete made by a chemical reaction with water. Other hydraulic cements that harden include:

[0052] Examples of liquid metals include metals and alloys with melting points below about 100°C (field metals). Examples include field's metal, wood metal and rose metal.

[0053] The method does not require layer-by-layer deposition. Instead, the nozzle is It is possible to move and push in any direction in the The printed product is stronger and more durable than those obtained from layer-based printing methods. The resulting molded article can have a more uniform material consistency and surface finish.

[0054] 1.2. Deposition The methods described herein use syringe-type nozzles with openings of various shapes and sizes. The method may also use a 1:1, 2:1, 1:2, or other ratio of input materials. The size and shape of the nozzle may be determined by the following: The shape can accommodate various viscosities and various extrusion shapes or feature sizes. Higher viscosity materials require larger nozzles and higher pressures, but the For low-pressure materials, smaller nozzles and lower pressures can be used. The extrusion pressure is Actuation can be pneumatic or mechanical. Either actuation technique can be used to achieve the desired effect. Controlling the amount of liquid deposited accurately and stopping to prevent remaining liquid from being pushed out In some cases, it is also possible to physically remove the material. The nozzle size allows for increased feature size and resolution of printed parts. It is also possible to improve resolution by increasing the amount of material and speed. The deposition rate, nozzle size, and pressure in the cylinder are all interrelated. For example, to print faster, you can change the nozzle size or pressure. Either can be increased, and if neither is increased, the nozzle moves The volume of material extruded per unit distance decreases as the nozzle velocity increases. In other words, by changing the nozzle size or the applied pressure, the solidification material affects the rate at which the solidified material is extruded from the nozzle, and thus the rate at which the solidified material is deposited. Also, by changing the shape of the nozzle opening, it is possible to affect the three-dimensional Various effects similar to calligraphy techniques can also be created in the printed parts. Nozzles having a square, diamond, V-shape, U-shape, C-shape or virtually any other shape A variety of feature profiles can be formed using the nozzle. An example is shown in Figure 5. Any of the components may be used interchangeably in the system. For example, two nozzles can be used at the same time. It is possible to deposit different materials simultaneously. Alternatively, a tool changer can be used to deposit a variety of materials. Various nozzle changes allow for different feature sizes, materials and / or profiles This allows for the creation of a single complex design having

[0055] The mixing tip 140 is also used to completely mix the two-part solidifying material for chemical hardening. Liquid materials have a variety of hardening times, ranging from a few seconds to a few minutes or hours. The liquid materials may also have a variety of final set properties, including high stiffness (e.g. acrylic butadiene styrene (ABS) plastics; elastic (e.g. rubber expandable, flexible, or rigid foam; soluble (liquid); brittle; high temperature resistant; or In theory, any other property may be included. The liquid may also contain fillers and colorants. Virtually any color and viscosity can be achieved by using cartridges, continuous fill mechanism to change properties during operation, for multi-material printing or various By using multiple nozzles for tool replacement, which allows the use of various materials in different locations , can be changed.

[0056] 2. Gel-type printing media 2.1. Composition The gel is used as a medium in which the solidifying material is deposited. When the solidifying material is deposited The gel supports the solidified material such that the solidified material is suspended within the gel.

[0057] A variety of gels are suitable. One specific example of a gel that has been used is neutralized polystyrene. Triacrylic acid (Carbomer 940) gel. Carbomer in the range of 0.25 to 1% by weight. 940 is thoroughly mixed in water to ensure no lumps remain. The mixture has a viscosity of The carbomer mixture is diluted with sodium hydroxide (NOH) until the pH is neutral. The aqueous solution of aH) is slowly added and stirred gently to avoid air bubbles. The mixture then becomes a highly viscous gel.

[0058] As described below, the viscosity of the gel can be adjusted by adjusting the pH so that the gel can have various It may be capable of receiving and supporting objects of a certain density.

[0059] Adjusting the viscosity of the gel also affects how the nozzle moves through the gel. For example, the gel and solidification materials may affect the shape of the printed structures. If both are low viscosity, the solidified material may not stay precisely where it is deposited. By increasing the viscosity of the gel, the deposited solidified material flows through the gel. Alternatively, some of the particles may remain in the path they were deposited in, without being broken down. In embodiments, if the viscosity of the gel is too low, the viscosity of the solidification material is increased. It is also possible.

[0060] 2.2. Controlling the buoyancy of an object The amount of Carbomer 940 used in the gel is determined by the amount of subsequent support of foreign bodies, liquids or solids. (Levitation).

[0061] Higher percentages of carbomer result in gels with higher viscosity and shear stress. In this state, the gel has a density that is much lower or higher than the density of the gel itself. The material can be made to float. When the proportion of carbomer is 1% by weight, the gel is 1 It can levitate a 4-inch lead sphere.

[0062] A lower percentage of carbomer results in a gel with lower viscosity and shear stress. In this state, the gel is a material having a density much lower or higher than the density of the gel itself. When the proportion of carbomer is 0.25% by weight, the gel cannot be made to float. cannot levitate a 1 / 4 inch aluminum sphere.

[0063] The gel composition can be modified to suit the formation of a desired object. The viscosity of the gel may range from 20,000 cP to about 50,000 cP.

[0064] 2.3. Self-healing The gel is then filled with the gap in the gap area through which the nozzle has passed after the nozzle has moved through the gel. The gel can then self-heal by reforming the cup so that it closes. , air pockets in the gel are minimized. Lower shear stress (slower nozzle speed) This allows the gel to quickly self-heal as the nozzle passes through. By depositing the solidified material on a gel with a lower viscosity, the deposition nozzle orifice morphology High viscosity gels take longer to heal themselves. As a result, Before the gel can self-heal, liquid material flows into the cavity left by the device. This effectively stretches the circular deposit into droplets. The shape of the liquid material varies depending on the relative viscosity of the gel and the speed at which it passes through the nozzle. become.

[0065] 3. Manufacturing equipment 3.1. Gantry System The liquid extrusion process within the gel suspension is precisely controlled using at least three-axis CNC machines. A 3-axis gantry machine is used, and the cartridge and nozzle are attached to the Z axis. The nozzle can print three-dimensional structures in the gel. The nozzle is movable in all three directions (i.e., in the x, y, and z directions). cannot rotate around the z-axis (when used on a 3-axis machine). Typically, the part being printed , the nozzle is limited to a three-dimensional shape in which the nozzle is oriented vertically.

[0066] A 5-axis gantry machine can also be used. In a 5-axis machine, the nozzle is aligned in three straight lines. It can move in all directions (x, y, and z) and rotate around the A and B axes. Since the nozzle can be rotated, the solidified material does not necessarily deposit vertically. It's not necessary.

[0067] 3.2. Industrial Robot Arm In another embodiment, a six-axis industrial robot is used to move the nozzle through the gel. Typically, a six-axis industrial robot is capable of rotation on six different axes. As a result, the nozzles can be pointed in various directions, allowing for side-to-side printing. Alternatively, the nozzle may be rotated as it is moved through space. It allows for more freedom in terms of the orientation of the robot and its relationship to the print axis.

[0068] 3.3.Other Machines Other deposition machines such as the "Delta" robot and cable bot are also available. There are also distributed printing processes using autonomous robots. ) is also available. This method does not require highly specialized machinery, but rather multiple control Almost any computer numerically controlled (CNC) machine capable of moving in three dimensions with axes It can handle.

[0069] 3.4.Scale These methods all require high accuracy and / or high speed for large (several cubic meters) volumes depending on the application. The technology is scalable to large (microtoners) or small (a few cubic millimeters) printing volumes. When high precision small parts are required, gantry machines are used to produce extremely precise syringe tips. Conversely, if a very large structure is required, In this case, large gantry machines (tens of meters) or large industrial robots (over 5 meters) Theoretically, there is no limit to the size of the machine, but a large gel tank is required. As the scale increases, the amount of gel required and the size of the container also increases. For industrial products within a few meters of the glass, this method is extremely promising. This provides an extremely fast and precise method of printing with a wide range of materials.

[0070] 3.5. Speed ​​and Multiple Machines The manufacturing equipment outlined can be run at slow or fast speeds depending on the application, time constraints, or feature of the part being printed. Typically, the robot arm that controls the nozzle is made up of smaller parts. And for smaller features on the part, you need to move slower. Larger parts And for larger part features, the robot arm controlling the nozzle can move faster. Alternatively, larger features can be formed using one arm and smaller features can be moved If the layers are simultaneously formed using other arms, a multi-robot printing method can be used. This allows for the use of different materials or connecting parts, or other processes that would not be possible with a single machine. Shape is also possible.

[0071] 4.Speed 4.1. Supporting material The present invention is much faster than existing printing methods for several reasons. The first significant improvement is the elimination of excess design material for support. A variety of gels can support the deposited material, allowing for easy assembly using FDM, SLA, or many other methods. No printed support material is required. This reduces the amount of material that needs to be printed. Significantly reduce the time it takes to print and to remove excess material from the print For example, bracing components with overhanging features require supporting walls or columns. It can be printed immediately in three-dimensional space without the need for a computer.

[0072] By removing this limitation, it is possible to print using other printing methods that require a support. It is also possible to print extremely complex structures that cannot be made with a conventional laser. For example, a hollow structure with a hollow cavity can be printed. For structures with complex shapes within a single print, the support material fills the cavities of the printed part. Since it is necessary for the printed part to extend to other printed parts, it is difficult to manufacture it by other methods. This excess material may not be removable, limiting the complexity of possible shapes. In SLA or powder-based printing methods, the support material is These can also become trapped in the matrix and greatly increase the amount of material required for the part.

[0073] 4.2.Post-printing process By printing in a viscous gel with a solidifying material that is either chemically cured or air cured The methods described herein reduce or eliminate complex and time-consuming post-processing. Printing methods typically require a support removal step, in which the support structure is manually broken down. It may be necessary to break it down into an alcohol bath to remove any uncured polymer. There are also cleaning processes in the United States. These steps are toxic, expensive and extremely time consuming. FDM and Polyjet printing usually involve a support dissolution step. In this process, the part is placed in a bath to remove the support material. This can be a toxic and extremely time-consuming process. After printing the part for an extended period of time, the part The powder base must be placed in a bath for minutes or hours while the support is removed. The printing method for the source involves a very tedious and time-consuming excavation process. The user must then dig the part out of the powder bath. Using the methods described herein When a part is printed, it is immediately (or with a time delay depending on the material selection) ) can be cured, then simply reach in and pull out the part to instantly release the gel. The part can then simply be washed with water to remove excess gel. Simply spray and the finished product is ready for use. This simple post-printing process This will greatly expand the use of 3D printing in industrial applications, reduce hazards and make printing easier. This makes it more accessible to many people and improves the speed of post-processing.

[0074] 4.3.Layered Printing vs. Spatial Printing Spatial liquid deposition in a viscous gel medium allows for slice- and layer-based printing. Any complex structure can be created in 3D space without the need for software file preparation for printing. It is possible to print just that immediately.

[0075] In contrast, layer-by-layer processes require highly complex software and large files. The slicing process also reduces the failure rate or surface area of ​​the printed part. Often with increased roughness. Complex 3D models are algorithmically reconstructed along 2D paths. Because the structure needs to be constructed, shapes may be missing, paths may be inaccurate, or Or the texture of the material on each layer can reduce the resolution of the part. Similarly, this layer-by-layer process significantly reduces the strength of the printed part due to inhomogeneities. The method described herein does not involve a layer-by-layer printing process and allows for the printing of This allows for the creation of a perfectly uniform cross section within any orientation of the print path.

[0076] Similarly, the methods described herein provide for extremely fast printing when compared to layer-by-layer processes. When using layer-by-layer printing, the printing time is multiplied by the linear length of each 2D path. This can be calculated by multiplying the z-height by the number of slices in the z-direction. In the present method, the nozzle is rotated in any direction. It can be printed in any shape and size, and there is no need to print layer by layer, so the printed part Or the possibilities for object speed and shape can be significantly improved.

[0077] 5.Use 5.1. Printing in three-dimensional space The methods described herein allow small or large objects to be displayed as if they were 2D drawings or scans. Like Ketch, it is possible to print in three-dimensional space. The nozzle can be moved manually through the gel without the use of a multi-axis machine. In some embodiments, the robotic arm or gantry machine is manually moved through the gel. The robot arm or gantry machine can be moved manually. The software records when the robot arm or gantry machine is moved. This allows for the creation of a reproducible record of movements for subsequent automated production. In another embodiment, the gantry machine or robotic arm can be controlled by a controller. Cut.

[0078] In some of the methods described herein, the structures created are curves in 3D space. For example, a 3D curve can be modeled in modeling software and sent to a robot arm. This curve can be generated as a series of points in 3D space that the machine follows during the printing process. The output of modeling software is usually machine code (e.g. For example, G-Code, Shopbot Code, UR Code, or the specific CNC code being used. (and various other formats of code files associated with the machine). This process usually The tool path that is exported from the modeling software and then followed by the machine, layer by layer. In your slicing software, slice the STL / Mesh geometry into layers that form the tracts. The need to use imported STL files (or mesh geometry files) The slicing software generates machine code for a regular printer. In the method described herein using a machine, no slicing step is required, and the machine code is It is generated from a series of three-dimensional points in space based on the original 3D curve. For example, the machine code may include a parameter and a value. a parameter that adjusts or decreases (e.g., turning air pressure on and off); parameters that control the speed of the nozzle as it moves through the gel; and a parameter for adjusting the orientation of the nozzle as the machine moves the nozzle through the gel. It's okay to do that.

[0079] When connected to design software, modeling tools or VR headsets, The method described herein allows a designer to sketch or design in the air and simultaneously This allows for printing in the gel at the same speed and scale. This 1:1 design for size scale was limited by the time constraints inherent in physical manufacturing. This has never been realized before. Most of the fabrication methods were quick sketch models. This technique takes a lot of time (even if you draw it), so it can never be as fast as sketching. It can print parts as fast as a bot or human can move an arm through the air. .

[0080] 5.2. Printing on other items When a manufacturing machine (gantry or robot) picks up an object and places it in the gel, In this case, the machine is capable of liquid printing on, around or within the object. This capability allows for the sequential printing of materials with different properties in a single build. For example, when making a chair, a structure (or structure) made by another method is added to the gel. In the case of the metal structure, the back of the chair, which is usually made of soft rubber material, can be placed Then, the robot can be switched to print around the metal structure. Foam materials can be printed as chair seat cushions that are directly connected to the This allows the incorporation of fastening details such as screws, bolts or other connectors, making hybrid This allows for a wide variety of (flexible or rigid) objects with different materials. The fabric can be placed or placed into the gel, which serves as a substrate for further construction processes. can also be placed in the gel and printed on.

[0081] FIG. 7 illustrates the construction of a chair using the methods described herein. Metal frame 190 The chair cover and frame 180d can be placed in the tank 160 of gel 170. Printing on and / or around the surface of the metal frame 190 to form a flat upholstered surface for the chair. This method allows the formation of other components in the gel suspension (e.g., industrially produced This makes it possible to incorporate hybrid printing (components that have been molded using a laser).

[0082] 5.3.Curing time The printed solidifying material can be designed to cure very quickly or slowly depending on the application. Faster cure times can reduce overall production time, while slower cure times can allows for more complete bonding when printing intersecting paths. Also, slower curing Time is allowed to allow bonding of the liquid printed structures to objects placed in the gel. do.

[0083] 5.4. Complex Tool Paths Another potential advantage of this technique is that it allows the creation of fully interlocking 3D parts without the need for support material. Or it can be formed without filling the cavity. For example, a woven structure or Printing of woven or knit structures involves the use of multiple robots that simultaneously deposit liquid. This can be done using a toolkit or with complex tool paths that would not be possible otherwise. Using a 6-axis industrial robot, the process is almost calligraphy-like. Complex tool paths with various nozzle extrusion directions can be used. It is also possible to print under, next to or over other prints / objects in the gel. be.

[0084] 5.5.Post-processing Various forms of post-curing (such as UV or temperature settings to change the material's properties) After removing the part from the gel bath, the part can be washed with water to remove excess gel. or coating the part with some material to strengthen it. , coloring the part, and further hardening the part, or any number of post-treatments. For example, the gel or the wood or metal slide may be used When ceramic materials are printed in the gel, the printed parts are cured and removed. The ceramic can then be removed and placed in an oven for post-processing. Through a baking or sintering process after printing, as used in the manufacture of composites or metals, or many other interesting material properties can greatly improve the strength of the part. can be done.

[0085] 5.5. Use of Materials The elimination of printed support material and the truly three-dimensional nature of this printing method allows This method allows the printing part to use much less material. Similarly, layer-based methods and The support material printed in the laminations is less material used compared to the material required for the final part. This results in a significant waste in terms of the total amount of material. The method described herein avoids the waste of materials. stomach.

[0086] 6. Advantages and Improvements over Existing Methods The technologies include SLA, SLA, FDM, Polyjet and powder-based printing. This offers a significant improvement over existing 3D printing methods, including The reasons for this are: 1) the injection molding process 2) long print times compared to other manufacturing methods; 3) relatively small build volumes ,Limited practical applications; and 3) low quality printable plastics, etc. It can be said that only materials can be used, and the properties of these materials are inferior to those of industrial materials. The methods described herein significantly improve these problems.

[0087] The methods described herein can be used to fabricate supports for constructing overhanging or complex three-dimensional structures. Since no material is required, the structures can be formed significantly faster. and SLA technologies have the advantage of printing time and the need to remove the support manually or by dissolving it. The need for a support significantly increases the time after printing due to the need to The method is capable of printing identical complex three-dimensional shapes without the use of supports, and at the same time Eliminate the need for unnecessary additional materials, unnecessary printing time and unnecessary post-printing processes. Once a structure is printed and the solidification material solidifies (e.g., hardens), the structure The gel is removed and simply washed with water to complete the process. A gel material structure is used to make the printed object float, and the nozzle can move freely on three axes at any time. Allows for some non-layer-based printing.

[0088] The technology also increases printing speed by eliminating the requirement to print in successive layers. Almost all currently available printing methods print each layer individually. This reduces the time required to print tall or complex 3D shapes. Sophisticated digital "slicing" significantly increases the time it takes to create a file and produces large file sizes. For example, wireframe structures can be manufactured using FDM, SLA, SLS, or powder When printed using a base print or Polyjet, this structure is spun into many layers. The wire must be sliced ​​and then printed in a straight line path for each layer. The ends of the frame structure are supported by cantilevered and unsupported features that allow the printed surface to be It is also necessary to have a supporting material that is supported by the three-dimensional space. By simply drawing these lines, the support material and slices can be eliminated. Other configurations that improve printing speed compared to aerial three-dimensional printing methods include extrusion Another method is to have the machine move the nozzle before moving to the next layer or continuously. This requires the material to cure or harden before it can be applied to the robot or printer. The speed at which the linters can move is significantly reduced. Because it is suspended in the gel in the space, the nozzle continues to move quickly and floats behind the nozzle path. It is possible to continue to extrude material which is then gradually solidified (e.g., chemically hardened). Due to these factors, it is believed that printing speed can be improved by an order of magnitude compared to conventional printing methods. can be done.

[0089] Compared to conventional three-dimensional printing methods, the method described herein allows for extremely compact, high-resolution The method is scalable from small to large scale. This is significantly faster than the conventional method, so you can build much larger structures in less time. For example, A cubic inch of material can take 24-48 hours to print on an SLA machine, The method described herein allows printing in minutes and is compatible with larger gel tanks. and scalability by using larger industrial robots or gantry machines. This makes it possible to produce extremely large structures extremely quickly. The speed and scale of printing is comparable to other industrial methods such as injection molding or machining. Especially considering the assembly time of conventional products, the method described herein can reduce the time required to assemble the product. Since the entire part can be printed at the same time, no assembly is required, greatly reducing the manufacturing process. There is a possibility that it will change.

[0090] One of the most notable advances over traditional 3D printing methods is the improvement in material properties. The method involves printing a solidifying material in a liquid or molten state, then chemically hardening the material. Therefore, realistic, industrially produced materials can be used. Some examples of materials that can be used are: For example, polyurethane (PU) rubber, foam, plastic, or any other liquid or FDM printing produces a filament that is then melted into a , which then needs to be heated and extruded in liquid form, and then cooled to form a three-dimensional structure. This method limits the types of materials that can be used and limits the layering and assembly involved in the FDM printing process. This property significantly reduces the structural integrity of printed parts compared to injection molding. SLS printing requires that the material be powdered and then sintered, making it difficult to use. The materials are further limited because the range of materials that can be used is limited. , using the same materials currently available in many industrial manufacturing processes, does not require heating, sintering or hot extrusion, but can be formed by chemical or other methods (e.g., photopolymerization) Also, because the method does not rely on successive build-up, the parts can be assembled in a similar manner to traditional manufacturing. The method described herein can be as strong as the part formed by the method. , liquid slurry wood, biomaterials, low temperature liquid metals, cement, or gel extrusion onto supports It can also be used to print other types of materials.

[0091] 7.Applications The methods described herein can be used to make a variety of products, including, for example, clothing and and sporting goods; fabrication and manufacturing; aeronautical and automotive applications; furniture and interior products; architecture , Engineering and Construction; Toys and Consumer Goods, etc. List some examples of products that fall into the category.

[0092] Clothing and Sporting Goods: 1:1 Sporting Goods (Bikes, Boards, Boots, Shoes, Helmets) printing on mats, pads, etc.; printed fabrics; in-store applications or for high-tech appeal Marketing / Commercial / PR uses using innovative new methods; existing manufacturing methods Faster than 100% customization and industrial quality materials (foam, rubber, plastic, etc.) Large or small parts made of plastic; physical 3D 1:1 size / speed sketching A new design method using guiding.

[0093] Fabrication and manufacturing: large-scale tooling, prototyping yping and fixturing; the speed of existing manufacturing methods can be exceeded and highly customized Customized, large or small, made of industrial quality materials (foam, rubber, plastic) small parts; hybrid approaches using multiple manufacturing methods (i.e. welding or casting) A fabricated metal part is inserted into the gel and liquid printed parts are applied in / around / on the metal part. (Receive).

[0094] Aviation and Automotive Applications: Large printed parts for interior applications (panels, seats, shades, dashes boards, ceilings, floors); medium-sized printed parts (seat cushions / structures, engine parts, brackets kits, connectors); large printed parts for external panels; tooling, prototypes Manufacturing and part manufacturing; can exceed the speed of existing manufacturing methods and can be highly customized, Large or small parts made of industrial quality materials (foam, rubber, plastic); physical A new design methodology using 3D 1:1 size / speed sketching.

[0095] Furniture and interior products: large printing parts for interior applications (screens, fixtures, etc.); medium printing Parts (seat cushions, seat structures, backrests / fabrics, tables, desks, stools , shelves, etc.); tooling, prototyping and fixture making; in-store or high-tech appeal Marketing / Commercial / PR uses with innovative new ways to It can exceed the speed of existing manufacturing methods and produce highly customized, industrial quality materials (foam Large or small parts made of metal (such as steel, rubber, plastic); physical three-dimensional 1:1 size / speed A new design method using degree sketching.

[0096] Architecture, Engineering and Construction: Large tool making (blades, concrete work, Support structure); Final structure (walls, surfaces, skins / panels, 1:1 details); Speed / scale On-site fabrication method for construction; using physical 3D 1:1 size / speed sketching A new way to design.

[0097] Toys and Consumer Goods: 1:1 Printing of Consumer Goods / Toys (Bikes, Boards, Boots, Shoes, Helmets , pads, etc.); highly customized, which can exceed the speed of existing manufacturing methods. Large or small parts made of industrial quality materials (foam, rubber, plastic); physical A new design method using 3D 1:1 size / speed sketching. Related Applications

[0098] The teachings of all patents, publications and references cited herein are incorporated by reference in their entirety. No. 6,399,423, which is incorporated herein by reference.

[0099] Although exemplary embodiments have been specifically described and illustrated, those skilled in the art will appreciate that the present invention Without departing from the scope of the embodiments encompassed by the appended claims, modifications in form and detail may be made. It will be understood that various modifications may be made to the disclosed subject matter. The present invention includes the following embodiments. [Aspect 1] a) placing a nozzle into a gel within a gel container; b) positioning the nozzle within the gel while depositing solidified material exiting the nozzle; and changing the gel to support the solidification material at the location where the solidification material is deposited. That being said; c) solidifying the solidification material to form a three-dimensional solid object; A method for manufacturing a three-dimensional object comprising the steps of: [Aspect 2] In the method of claim 1, the nozzle is mounted on a multi-axis machine and the nozzle is placed in the gel. The changing of the position of the nozzle includes changing the position of one or more of the multi-axis machines to which the nozzle is attached. The method includes operating an axis. [Aspect 3] 3. The method of claim 1 or 2, further comprising depositing the solidified material exiting the nozzle. further comprising varying a rate at which the solidified material is deposited. [Aspect 4] 3. The method according to claim 1 or 2, further comprising: varying the position of the nozzle within the gel. and further comprising varying the position of the nozzle at a varying rate. [Aspect 5] 3. The method according to claim 1 or 2, further comprising: varying the position of the nozzle within the gel. and repositioning the gel container. [Aspect 6] 3. The method of claim 1, wherein solidifying the solidification material comprises: to light or heat. [Aspect 7] 3. The method of claim 1, wherein solidifying the solidification material comprises: and cooling the [Aspect 8] 3. The method of claim 1 or 2, wherein solidifying the solidification material comprises: exposing the solidified material to light while depositing the solidified material emerging from the substrate. [Aspect 9] The method according to claim 1 or 2, wherein the solidification material is a polymer, a rubber, a pulp, a pulp, a cellulose, a cellulose acetate ... The method may be foam, metal, concrete, or epoxy resin. [Aspect 10] 10. The method of claim 9, wherein the rubber is a silicone rubber. [Aspect 11] 3. The method of claim 1 or 2, wherein the hardness of the solidified material upon solidification is about Shore 00. Methods ranging from ~10 to about Shore 90D. [Aspect 12] 3. The method of claim 1 or 2, wherein the solidification material is a foam. [Aspect 13] 13. The method of claim 12, wherein the solidified foam has a density of about 3 lb / ft 3 ~about 30lb / ft 3 How to be. [Aspect 14] The method according to any one of the preceding claims, wherein the gel is a suspension. [Aspect 15] 15. The method of claim 14, wherein the gel comprises carbomer or polyacrylic acid. Law. [Aspect 16] In the method according to aspect 1 or 2, the viscosity of the gel is about 20,000 cP to about 500 How to be 00cP. [Aspect 17] The method according to any one of the first to second aspects, wherein the nozzle is circular, rectangular, square, diamond, A V-shaped, U-shaped, or C-shaped tip from which the solidified material exits is deposited. method. [Aspect 18] In the method according to the first or second aspect, the solidification material comprises two copolymerizable compounds. and solidifying the solidification material includes copolymerizing the two compounds. Law. [Aspect 19] 19. The method of claim 18, wherein the nozzle further comprises: The method includes a mixing section that mixes the two compounds as they exit the drain and are deposited. [Aspect 20] In the method according to aspect 1 or 2, the changing of the position of the nozzle comprises at least The nozzle may be moved within the gel in three to eight axes simultaneously, at any one time. Methods including: [Aspect 21] In the method according to aspect 1 or 2, the changing of the position of the nozzle comprises at least The nozzle can be moved in five to eight axes simultaneously, temporarily, in the gel. Methods including: [Aspect 22] In the method according to aspect 1 or 2, the changing of the position of the nozzle comprises at least The nozzle may be moved in three to six axes simultaneously, temporarily, in the gel. Methods including: [Aspect 23] In the method according to aspect 1 or 2, the changing of the position of the nozzle comprises at least varying the position of the nozzle within the gel in six axes simultaneously, all at once. . [Aspect 24] 3. The method of claim 1, wherein the changing of the position of the nozzle is the nozzle to deposit solidified material on, around, or within other objects in the nozzle. said method comprising: changing said position. [Aspect 25] 3. The method according to claim 1 or 2, wherein the nozzle is a first nozzle, and the solidification material is a first solidification material, the solid is a first solid, and the method further comprises: d) disposing a second nozzle within the gel container and into the gel; e) depositing a second solidifying material from the second nozzle while dispensing the second nozzle in the gel; and repositioning the nozzle such that the gel displaces the second solidification material. depositing the first and second solidification materials while supporting them in a deposited position; and causing the first and second materials to be in deposited contact; f) solidifying the second solidification material to form a second solid object, and a second solid body is joined as the three-dimensional object. The method includes: [Aspect 26] 26. The method of claim 25, wherein the first and second nozzles have tips with different shapes. How to do it. [Aspect 27] 26. The method of claim 25, wherein the first and second solidification materials are different materials. . [Aspect 28] a) a nozzle mounted on a multi-axis machine; b) means for extruding solidified material from said nozzle; c) a gel container; A three-dimensional object manufacturing apparatus comprising:

Claims

1. a) placing a nozzle into a gel, the gel being a carbomer gel, in a gel container; b) depositing a solidified material that exits the nozzle and becomes a part of a three-dimensional object; and repositioning the nozzle in the gel to cause the gel to transfer the solidification material to the solidification material. supporting the solidified material in a deposited position so that the solidified material is suspended within the gel; c) solidifying the solidification material in the gel to form a solid object that is a three-dimensional object. A method for producing a three-dimensional object, comprising: The nozzle is a first nozzle, the solidification material is a first solidification material, and the solid is a second nozzle. 1 solid, and the method further comprises: d) placing a second nozzle within the gel container; e) depositing a second solidifying material from the second nozzle while discharging the second nozzle in the gel. and changing the position of the nozzle so that the gel is able to displace the second solidification material. Depositing the first and second solidification materials while supporting them in a deposited position. and causing the first and second solidification materials to be in contact in a pile; f) solidifying the second solidification material to form a second solid object, and a second solid body is joined as the three-dimensional object; the gel returning to its original location after being moved by the first or second nozzle; The method wherein the gel is an aqueous gel.

2. 10. The method of claim 1, wherein the nozzle is mounted on a multi-axis machine and the gel is The changing of the position of the nozzle includes changing the position of one or more of the multi-axis machines to which the nozzle is attached. The method includes operating an axis of the

3. 3. The method of claim 1, further comprising depositing the solidified material exiting the nozzle. further comprising varying a rate at which the solidified material is deposited.

4. 3. The method of claim 1 or 2, further comprising varying the position of the nozzle in the gel. further comprising varying the position of the nozzle at a varying rate.

5. 3. The method of claim 1 or 2, further comprising varying the position of the nozzle in the gel. comprising changing the position of said gel container.

6. The method according to claim 1 or 2, wherein the solidifying material is solidified by: The method comprises exposing the material to light or heat.

7. The method according to claim 1 or 2, wherein the solidifying material is solidified by: and cooling the material.

8. 3. The method of claim 1, wherein the solidifying material is solidified by the nozzle. exposing the solidified material to light while depositing the solidified material exiting the nozzle.

9. 3. The method according to claim 1 or 2, wherein the solidification material is a polymer, a rubber, a pulp, Methods that are foam, metal, concrete, or epoxy resin.

10. 10. The method of claim 9, wherein the rubber is a silicone rubber.

11. 3. The method of claim 1, wherein the hardening material has a hardness of about Shore 0 when hardened. The method ranges from 0-10 to about Shore 90D.

12. 3. The method of claim 1 or 2, wherein the solidifying material is a foam.

13. 13. The method of claim 12, wherein the density of the solidified foam is about 3 lb / ft. ３ ~ Approximately 30lb / ft ３ How to be.

14. 3. The method of claim 1 or 2, wherein the gel is a suspension.

15. 3. The method of claim 1, wherein the viscosity of the gel is from about 20,000 cP to about 50 000cP.

16. 3. The method according to claim 1, wherein the nozzle is circular, rectangular, square, diamond shaped. The solidified material exiting the tip is deposited on the surface of the substrate. How to do it.

17. 3. The method according to claim 1 or 2, wherein the solidification material is a copolymer of two compounds. and solidifying the solidification material comprises copolymerizing the two compounds. method.

18. 18. The method of claim 17, wherein the nozzle further comprises: The method includes a mixing section that mixes the two compounds as they exit the nozzle and are deposited.

19. 3. The method of claim 2, wherein the changing of the position of the nozzle comprises at least one and varying the position of the nozzle within the gel in three to eight axes simultaneously. Law.

20. 3. The method of claim 2, wherein the changing of the position of the nozzle comprises at least one and varying the position of the nozzle within the gel in five to eight axes simultaneously. Law.

21. 3. The method of claim 2, wherein the changing of the position of the nozzle comprises at least one and varying the position of the nozzle within the gel in three to six axes simultaneously over time. Law.

22. 3. The method of claim 2, wherein the changing of the position of the nozzle comprises at least one and varying the position of the nozzle within the gel in six axes simultaneously over time.

23. 3. The method of claim 1, wherein the changing of the position of the nozzle comprises: The nozzle for depositing solidified material onto, around, or within other objects in the gel. changing said position of.

24. 10. The method of claim 1, wherein the first and second nozzles have tips of different shapes. How to do it.

25. 10. The method of claim 1, wherein the first and second solidification materials are different materials. 。

26. a) a first nozzle and a second nozzle mounted on a multi-axis machine; b) extruding a first solidification material from the first nozzle and a second solidification material from the second nozzle. A means for pushing out; c) a gel container, the multi-axis machine positions the first nozzle in the gel within the gel container; The gel supports the first and second solidification materials at the locations where the solidification materials are deposited. wherein the first and second solidification materials are suspended in the gel; The multi-axis machine is adapted to rotate the solidified material through the first and second nozzles to become a part of the three-dimensional object. repositioning the first and second nozzles within the gel while depositing material; Depositing the first and second solidification materials includes depositing the first and second solidification materials. The contact is made in a state where the first and second solid bodies are joined as the three-dimensional object; the gel returning to its original location after being moved by the first or second nozzle; The gel is a carbomer gel and is an aqueous gel.

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