Selective Deposition Modeling Wax Compositions for Investment Casting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current solid freeform fabrication techniques face challenges in finding suitable materials for selective deposition modeling that can be dispensed through ink-jet type print heads, offering sufficient strength, accuracy, and handling properties, while also being suitable for investment casting processes.
Innovation Solution
The use of specific combinations of build and support materials, including a build hydrocarbon wax and a support hydrocarbon alcohol wax, each with tailored viscosity and melting temperature ranges, along with viscosity modifiers, to enable accurate and strong three-dimensional object creation, and a method for separating the support material using a polar solvent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pattern waxes are used for investment casting, then casting suitability is improved, but dispensability through ink-jet print heads deteriorates due to high viscosity
Solution Approach 1:
The patent modifies the physical parameters of pattern waxes by blending them with viscosity modifiers and adjusting composition ratios. This reduces viscosity to enable ink-jet dispensing while maintaining casting suitability through controlled modification of wax properties.
Solution Approach 2:
The invention creates composite materials by combining pattern waxes with viscosity modifiers and other additives. This composite approach allows the material to simultaneously achieve low viscosity for dispensing and appropriate rheological properties for casting applications.
2Ease of manufacture
If pattern waxes with appropriate viscosity are used, then dispensability is improved, but layer to layer distortion increases
Solution Approach 1:
The patent carefully controls viscosity parameters within specific ranges (e.g., 10-100 cP at processing temperature) to balance dispensability through ink-jet heads with minimal layer distortion during deposition.
Solution Approach 2:
The invention applies different functional components to different aspects of the material: base waxes provide structural integrity to minimize distortion, while viscosity modifiers enable dispensing. This local functional assignment resolves the contradiction between ease of manufacture and manufacturing precision.
3Ease of operation
If materials with high toughness are used, then handling properties are improved, but material strength may be compromised for accurate part formation
Solution Approach 1:
The patent adjusts material parameters including toughness and strength through composition control. By modifying wax blend ratios and additive concentrations, the material achieves optimal toughness for handling while maintaining sufficient strength for accurate part formation and dimensional stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These materials allow for the production of three-dimensional objects with improved dimensional accuracy and strength, suitable for investment casting, and enable efficient separation of the support material from the build object, maintaining the object's accuracy and resolution.
Implementation Method 1
heating the material to a flowable temperature then selectively dispensing the material and allowing it to cool
Implementation Method 2
these previous materials tend to have latent heat properties that are not suitable for quick heat dissipation and fast three-dimensional object building
Implementation Method 3
a method for separating the support material using a polar solvent
Data Source
AI summary
There is provided compositions and methods for producing three-dimensional objects by selective deposition modeling with a polar build material and a non-polar support material. The build material comprises a hydrocarbon wax material and a viscosity modifier, and the support material comprises a hydrocarbon alcohol wax material and a viscosity modifier. After the selective deposition modeling process has been completed, the object can be placed in a bath of polar solvent to remove the support material. The particular materials provided herein, and the post-processing methods associated therewith, provide for improved part quality of the three-dimensional object and for improved post-processing techniques. The three-dimensional objects can subsequently be used in a number of applications, such as patterns for investment casting.