Uses of support material in solid freeform fabrication systems

Abstract

The present invention is drawn to solid freeform fabrication systems and methods for producing three-dimensional objects. The system can include build material configured to be deposited in layers to form a three-dimensional object; and support material configured to be deposited adjacent to the build material for supporting the build material during formation of the three-dimensional object. The support material can also be configured to form a feature that imparts a predetermined property within the three-dimensional object.

1 . A solid freeform fabrication system for producing a three-dimensional object with embedded features, comprising: 
 build material configured to be deposited in layers to form a three-dimensional object; and    support material configured to be deposited adjacent to the build material for supporting the build material during formation of the three-dimensional object, said support material also being configured to form a feature that imparts a predetermined property within the three-dimensional object.    
   
   
       2 . A system as in  claim 1 , wherein the build material is a liquid that is configured to be deposited in layers using an ink-jet printhead.  
   
   
       3 . A system as in  claim 2 , wherein the build material is UV curable.  
   
   
       4 . A system as in  claim 1 , wherein the feature is within a cavity defined at least in part by the build material.  
   
   
       5 . A system as in  claim 4 , wherein the cavity is a closed cavity that is completely defined by build material.  
   
   
       6 . A system as in  claim 4 , wherein the cavity is an open cavity that is partially defined by the build material and is partially open to a surface of the three-dimensional object.  
   
   
       7 . A system as in  claim 1 , where the feature imparts color.  
   
   
       8 . A system as in  claim 1 , where the feature imparts conductance.  
   
   
       9 . A system as in  claim 7 , wherein the build material is at least partially transparent.  
   
   
       10 . A system as in  claim 8 , wherein the feature also includes additional build material.  
   
   
       11 . A method for solid freeform fabrication of three-dimensional objects, comprising: 
 layering build material to form a three-dimensional object, said three-dimensional object including a cavity therein that is at least in part defined by the build material;    supporting overhangs formed during the layering step using a first portion of support material;    depositing a second portion of the support material in said cavity, wherein at least the second portion of the support material is configured to form a feature that imparts a predetermined property within the three-dimensional object; and    removing the first portion of the support material from the three-dimensional object.    
   
   
       12 . A method as in  claim 11 , wherein the step of layering includes step of jetting build material to form multiple layers of build material.  
   
   
       13 . A method as in  claim 12 , further comprising the step of UV curing the build material after the jetting step.  
   
   
       14 . A method as in  claim 11 , wherein the first portion and the second portion of the support material are of the same composition.  
   
   
       15 . A method as in  claim 11 , further including the step of depositing build material within the cavity.  
   
   
       16 . A method as in  claim 15 , wherein the build material is at least partially transparent, the support material imparts a color, and the build material and the support material are both present within the cavity at a 1:99 to 99:1 build material to support material volume ratio.  
   
   
       17 . A method as in  claim 11 , where the feature imparts color.  
   
   
       18 . A method as in  claim 11 , where the feature imparts conductance.  
   
   
       19 . A method as in  claim 11 , further comprising the preliminary step of predetermining the location to place cavities within the three-dimensional object.  
   
   
       20 . A method as in  claim 19 , wherein the step of predetermining is carried out with the assistance of a computer modeling system.