System and method for printing and supporting three dimensional objects

Abstract

A method for printing and supporting a three-dimensional (3-D) object is provided. The method of printing can include dispensing a first interface material for the construction of the three-dimensional object, dispensing a second interface material to form a support structure for supporting the three-dimensional object and dispensing a third interface material which may be used to separate the support structure from the 3-D object Disclosed also a method for producing a 3-D model containing various kinds of inserts.

1 . A method for building three-dimensional objects, said method comprising: 
 dispensing a first material used to form at least the three-dimensional object;    dispensing a second material used to form at least part of a support structure; and    dispensing a third material between said 3-D object and said support structure to form a release layer.    
     
     
         2 . The method of  claim 1  wherein at least said first material is a photopolymer and at least the three-dimensional object is formed after being irradiated by electromagnetic radiation.  
     
     
         3 . The method of  claim 1  wherein said second material is a photopolymer and the support structure is formed after being irradiated by electromagnetic radiation.  
     
     
         4 . The method of  claim 1  wherein said third material is a photopolymer and the release layer is formed after being irradiated by electromagnetic radiation.  
     
     
         5 . The method of  claim 1  wherein said support structure comprises said first material.  
     
     
         6 . The method of  claim 1  wherein said second and third materials are the same substance.  
     
     
         7 . The method of  claim 1  wherein said release layer is softer than said support structure, and said support structure is softer than said 3-D object.  
     
     
         8 . The method of  claim 1  comprising separating said support structure and release layer from said 3-D object thereby to produce a three dimensional object comprised of said first material.  
     
     
         9 . The method according to  claim 1 , comprising subjecting said second material to a solvent or to radiation thereby to cause the support structure to weaken.  
     
     
         10 . The method according to  claim 1 , wherein said support structure and release layer are at least partly liquid or paste after curing.  
     
     
         11 . The method according to  claim 1 , where said support structure comprises a container capable of confining said support material.  
     
     
         12 . The method according to  claim 1 , further comprising constructing at least one support pillar of said first material within said support structure.  
     
     
         13 . The method according to  claim 12 , further comprising constructing at least one connecting membrane of first material attached to said at least one support pillar.  
     
     
         14 . A system for building three-dimensional objects, said system comprising: 
 a controller, and    a jetting head capable of selectively dispensing: 
 a first material used to form at least the three-dimensional object;  
 a second material used to form at least part of a support structure; and  
 a third material between said 3-D object and said support structure used to form a release layer.  
   
     
     
         15 . The system of  claim 14  wherein at least said first material is a photopolymer and at least the three-dimensional object is formed after being irradiated by electromagnetic radiation.  
     
     
         16 . The system of  claim 14  wherein said second material is a photopolymer and the support structure is formed after being irradiated by electromagnetic radiation.  
     
     
         17 . The system of  claim 14  wherein said third material is a photopolymer and the release layer is formed after being irradiated by electromagnetic radiation.  
     
     
         18 . The system of  claim 14  wherein said support structure comprises said first material.  
     
     
         19 . The system of  claim 14 , wherein said support structure and release layer are at least partly liquid or paste after curing.  
     
     
         20 . The system of  claim 14 , where said support structure comprises a container capable of confining said support material.  
     
     
         21 . A method for building three-dimensional objects, said method comprising: 
 dispensing a curable build material to form the 3-D object and part of the support structure;    dispensing a support material to form part of the support structure, the build material being solid after curing and the support material being liquid after curing; and    forming a support structure comprising a container capable of holding said support material    
     
     
         22 . The method according to  claim 21 , wherein said container comprises a base, a plurality of walls and an open top.  
     
     
         23 . The method according to  claim 21 , wherein said container comprises at least one nib projecting from at least one of said walls, wherein said at least one nib is capable of restraining the movement of a three dimensional object.  
     
     
         24 . The method according to  claim 21 , wherein said container comprises build material.  
     
     
         25 . The method according to  claim 21 , wherein each of said build material, support material and container are formed in layers.  
     
     
         26 . A system for building three-dimensional objects, said system comprising: 
 a controller; and    a material dispenser capable of dispensing: 
 a curable build material to form the 3-D object and part of a support structure; and  
 a support material to form part of the support structure, the build material being solid after curing and the support material being liquid after curing; wherein the material dispenser is capable of forming a support structure comprising a container capable of holding said support material.  
   
     
     
         27 . The system according to  claim 26 , wherein said container comprises a base, a plurality of walls and an open top.  
     
     
         28 . The system according to  claim 26 , wherein said container comprises at least one nib projecting from at least one of said walls, wherein said at least one nib is capable of restraining the movement of a three dimensional object.  
     
     
         29 . The system according to  claim 26 , wherein said container material is identical to said build material.  
     
     
         30 . The system according to  claim 26 , wherein each of said build material, support material and container material are deposited in layers.  
     
     
         31 . A method for building three-dimensional objects, said method comprising: 
 dispensing a build material;    dispensing a second material forming a support structure; and    constructing a support pillar to support an object comprised of said build material.    
     
     
         32 . The method according to  claim 31 , comprising constructing membranes connected to said support pillar.  
     
     
         33 . The method according to  claim 31 , wherein said at least one support pillar is comprised of said build material.  
     
     
         34 . The method according to  claim 31 , wherein said at least one support pillar is comprised of said build material and said second material.  
     
     
         35 . The method according to  claim 31 , wherein said at least one support pillar comprises a plurality of layers and wherein the topmost layer of said at least one support pillar is adjacent to an object being supported.  
     
     
         36 . The method according to  claim 31 , wherein said upper portion of said at least one support pillar is tapered.  
     
     
         37 . The method according to  claim 31 , wherein each of said build material, second material and pillar are deposited in layers.  
     
     
         38 . The method according to  claim 31 , wherein the topmost layer of said at least one support pillar comprises said second material.  
     
     
         39 . The method according to  claim 31 , wherein the topmost layer of said at least one support pillar comprises a third material, said third material being softer than the material forming the remainder of said at least one support pillar.  
     
     
         40 . A system for building three-dimensional objects, said system comprising: 
 dispenser capable of dispensing: 
 a build material;  
 second material forming a support structure; and  
 said dispenser constructing a support pillar to support an object comprised of said build material.  
   
     
     
         41 . The system according to  claim 40 , wherein said dispenser is capable of material forming dispensing constructing membranes connected to said support pillar.  
     
     
         42 . The system according to  claim 40 , wherein said at least one support pillar is comprised of said build material.  
     
     
         43 . The system according to  claim 40 , wherein said at least one support pillar is comprised of said build material and said second material.  
     
     
         44 . The system according to  claim 40 , wherein said at least one support pillar comprises a plurality of layers and wherein the topmost layer of said at least one support pillar is adjacent to an object being supported.  
     
     
         45 . The system according to  claim 40 , wherein the topmost layer of said at least one support pillar comprises said second material.  
     
     
         46 . The system according to  claim 40 , wherein the topmost layer of said at least one support pillar comprises a third material, said third material being softer than the material forming the remainder of the pillar.  
     
     
         47 . The system according to  claim 40 , wherein said upper portion of said at least one support pillar is tapered.  
     
     
         48 . The system according to  claim 40 , wherein each of said build material, second material and pillar are deposited in layers.  
     
     
         49 . A method for building three-dimensional objects, said method comprising: 
 dispensing a first material for the construction of the three-dimensional object;    dispensing a support material forming a support structure for supporting said three-dimensional object; and    inserting a support insert.    
     
     
         50 . The method of  claim 49  wherein the support insert comprises a third material.  
     
     
         51 . The method of  claim 49  wherein the support insert includes plastic.  
     
     
         52 . The method of  claim 49  wherein the support insert includes metal.  
     
     
         53 . The method of  claim 49  wherein the support insert is a plate shaped member.  
     
     
         54 . The method of  claim 49  wherein the support insert is a skewed member.  
     
     
         55 . The method of  claim 49  wherein the support insert includes at least threads.  
     
     
         56 . The method of  claim 49  wherein the support insert is flexible.  
     
     
         57 . The method of  claim 49  wherein the support insert is more rigid than the support material, after said support material is cured.  
     
     
         58 . A system for building three-dimensional objects, said system comprising: 
 a build material jetting means for dispensing build material;    a support material jetting means for dispensing support material; and    a release material jetting means for dispensing release material between said built and support materials.    
     
     
         59 . A system for building three-dimensional objects, said system comprising: 
 a controller means;    a material dispenser means for dispensing: 
 build material having a first modulus of elasticity;  
 container material having a second modulus of elasticity; and  
 support material having a third modulus of elasticity and being held in a container comprised of said container material.  
   
     
     
         60 . A system for building three-dimensional objects, said system comprising: 
 a dispenser means for dispensing: 
 a build material;  
 a second material forming a support structure; and  
 said dispenser means constructing a support pillar to support an object comprised of said build material.