Method and system for creating three-dimensional objects by additive manufacturing.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- UNIVERSITY OF TASMANIA
- Filing Date
- 2024-06-10
- Publication Date
- 2026-06-24
Smart Images
Figure 2026520720000001_ABST
Abstract
Claims
1. A method for forming a three-dimensional object layer by layer on a work surface using two or more photocurable inks, wherein the work surface is configured to be movable relative to an ink deposition structure and a light source, and the method includes forming the layers of the three-dimensional object, and forming the layers is Depositing the first photocurable ink, Selectively exposing the deposited first ink to the light source, thereby curing at least a portion of the deposited first ink, Depositing a second photocurable ink, The method includes selectively exposing the deposited second ink to the light source, thereby curing at least a portion of the deposited second ink, A method wherein the cured portions of the first ink and the second ink form at least a portion of the layers of the three-dimensional object.
2. The method according to claim 1, wherein the portion of the deposited first ink is cured before the second ink is deposited.
3. The method according to claim 2, wherein after curing the portion of the first ink and before depositing the second ink, the remaining uncured portion of the first ink is substantially removed.
4. The method according to claim 1, wherein each of the first and second inks is deposited before the curing of either the first or second ink.
5. The method according to claim 4, wherein after curing the portion of the second ink, the remaining uncured portion of the second ink is substantially removed.
6. The method according to any one of claims 1 to 5, wherein the deposition structure is positioned at a first height above the work surface during the deposition of the first ink, and the deposition structure is positioned at a second height above the work surface during the deposition of the second ink.
7. The method according to claim 6, wherein each of the first height and the second height is selected from a range of about 20 μm to about 1 mm.
8. The method according to claim 6 or 7, wherein the first height is approximately the same as the second height.
9. The method according to any one of claims 1 to 8, wherein the ink deposition configuration comprises two or more ink dispensers, and each of the two or more ink dispensers is configured to distribute its respective ink.
10. The method according to claim 9, wherein each of the ink dispensers comprises one of a syringe or an inkjet head.
11. The method according to claim 9 or 10, wherein forming the layer of the three-dimensional object includes moving the work surface relative to the ink deposition configuration, and the ink deposition configuration selectively operates one or more of the ink dispensers at different relative positions of the work surface and the ink deposition configuration, thereby depositing one or more of the ink at those positions.
12. Each of the two or more photocurable inks contains a precursor material for forming a polymer, and the formation of the polymer is The reactive thiol group of the ink is reacted with an ene compound of the ink containing one or more reactive ene groups under conditions that promote the thiol-ene reaction. The reactive thiol group of the ink is reacted with an ine compound of the ink containing one or more reactive ine groups under conditions that promote the thiol-in reaction. The method according to any one of claims 1 to 11, comprising reacting the reactive thiol group of the ink with an acrylate compound of the ink containing one or more reactive acrylate groups under conditions that promote a thiol-acrylate reaction.
13. The method according to any one of claims 1 to 12, wherein each of the two or more photocurable inks comprises one or more organosilicon monomers.
14. The method according to claim 13, wherein one or more organosilicon monomers are selected from the group consisting of functionalized polysiloxane, polycarbosiloxane, polysilsesquioxane, polycarbosilane, polysilylcarbodiimide, polysilsesquicarbodiimide, polysilazane, polysilsesquiazan, polyborosilane, polyborosiloxane, and polyborosilazane.
15. The method according to any one of claims 1 to 14, wherein one or more of the photocurable inks include ceramic particles.
16. The method according to any one of claims 1 to 15, wherein one or more of the photocurable inks comprises one or more additives selected from the group consisting of free radical scavengers, photoblockers, and photoinitiators.
17. The method according to any one of claims 1 to 16, wherein one or more inks have a viscosity in the range of about 0.1 Pa.s to 1000 Pa.s.
18. The method according to any one of claims 1 to 17, wherein selectively exposing the deposited ink to the light source comprises generating a pattern of photocured light and projecting the pattern onto at least a portion of the deposited ink.
19. The method according to any one of claims 1 to 18, wherein the exposure to the light source is performed for an exposure time of 1 millisecond to 1 hour.
20. The method according to any one of claims 1 to 19, wherein the light source emits photocuring light having a wavelength in the UV or visible spectrum.
21. The method according to claim 20, wherein the light source emits photocuring light having a wavelength in the range of about 360 nm to about 420 nm.
22. A method for forming a three-dimensional object layer by layer on a work surface using one or more photocurable inks, wherein the work surface is configured to be movable relative to an ink deposition structure and a light source, and the method comprises forming the at least one layer on at least one layer of the three-dimensional object, wherein the formation is Depositing a photocurable ink to a first thickness determined in a direction perpendicular to the plane of the work surface, The method includes selectively exposing the deposited ink to the light source, thereby curing at least a portion of the deposited first ink. A method wherein the selective exposure of the deposited ink to the light source is configured such that the cured portion extends to a curing thickness determined in a direction perpendicular to the plane of the work surface, wherein the curing thickness is less than or substantially equal to the deposition thickness.
23. The method according to claim 22, wherein the remaining uncured portion of the deposited ink is substantially removed, thereby exposing the surface of the cured portion.
24. The method according to claim 23, wherein the subsequent layer of the three-dimensional object is formed to cover at least a portion of the exposed surface.
25. Forming the layer of the aforementioned three-dimensional object is further, The second photocurable ink is deposited to a second thickness determined in a direction perpendicular to the plane of the work surface, The method includes selectively exposing the deposited second ink to the light source, thereby curing at least a portion of the deposited second ink, The method according to any one of claims 22 to 24, wherein the cured portions of the first ink and the second ink form at least a portion of the layer of the three-dimensional object, and selective exposure of the deposited second ink to the light source is configured such that the cured portions of the second ink extend to a curing thickness determined in a direction perpendicular to the plane of the work surface, and the curing thickness of the second ink is less than or substantially equal to the deposition thickness of the second ink.
26. A method for forming a three-dimensional object layer by layer on a work surface using one or more photocurable inks, wherein the work surface is configured to be movable relative to an ink deposition structure and a light source, and the method includes forming the layers of the three-dimensional object, and forming the layers is Depositing a light-curing ink, The method includes selectively exposing the deposited ink to the light source, thereby curing at least a portion of the deposited ink, A method wherein the hardened portion forms at least a part of the layer of the three-dimensional object.
27. The method according to claim 26, wherein the photocurable ink has high oxygen resistance.
28. A system for fabricating a three-dimensional object layer by layer using one or more photocurable inks, wherein the system is The work surface on which the three-dimensional object is formed, An ink deposition configuration configured to deposit layers containing one or more photocurable inks under spatial control, wherein each layer is in an initial ink deposition state, The system comprises a light source configured to selectively expose each initial ink deposition to light such that at least a portion of the initial ink deposition is photocured to provide a solidified layer for the three-dimensional object, A system in which the ink deposition configuration and the relative positioning of the work surface with respect to the light source are variable.
29. The system according to claim 28, further comprising an ink removal configuration configured to remove at least a portion of the uncured portion of the initial ink deposition.
30. The system according to claim 28, configured to carry out the method described in any one of claims 22 to 27.
31. The system according to claim 28 or 29, wherein the system is configured to form the three-dimensional object using two or more photocurable inks, and the cured portions of the two or more inks form at least a portion of the layers of the three-dimensional object.
32. The system according to claim 31, configured to carry out the method described in any one of claims 1 to 21.