Additive Process for Production of Dimensionally Stable Three Dimensional Objects

Abstract

Generally, compositions and methods of producing dimensionally stable three dimensional objects using an additive build up process. Specifically, materials combinable in an additive build up process using a materials printer for the production of stable three dimensional molds useful in the production of molded or formed parts.

1 - 34 . (canceled) 
     
     
         35 . A composition, comprising:
 a binder liquid adapted to successively combine with a build material to build up an object, said binder liquid including an amount of acrylic co-polymer in a range of between about 30% to about 100% v/v.   
     
     
         36 . The composition of  claim 35 , wherein said amount acrylic co-polymer is between about 30% to about 75% v/v. 
     
     
         37 . The composition of  claim 36 , wherein said amount of acrylic co-polymer is selected from the group consisting of: about 35% to about 45% v/v, about 40% to about 50% v/v, about 45% to about 55% v/v, about 50% to about 60% v/v, about 55% to about 65% v/v, and about 60% to about 70% v/v. 
     
     
         38 . The composition of  claim 37 , wherein said amount of acrylic co-polymer comprises an amount of Forton VF-812. 
     
     
         39 . The composition of  claim 36 , wherein said binder liquid further comprises an amount of water of up to about 50% v/v. 
     
     
         40 . The composition of  claim 39 , wherein said amount of water is selected from the group consisting of: about 1% to about 10%, about 5% to about 15%, about 10% to about 20%, about 15% to about 25%, about 20% to about 30%, about 25% to about 35%, about 30% to about 40%, and about 35% to about 45%. 
     
     
         41 . The composition of  claim 36 , wherein said binder liquid further comprises an amount of isopropyl alcohol. 
     
     
         42 . The composition of  claim 41 , wherein said amount of isopropyl alcohol is up to about 20% v/v. 
     
     
         43 . The composition of  claim 42 , wherein said amount of isopropyl alcohol is selected from the group consisting of: about 1% to about 3% v/v, about 2% to about 4% v/v, about 3% to about 5% v/v, about 4% to about 6% v/v, about 5% to about 7% v/v, about 6% to about 8% v/v, about 7% to about 9% v/v, about 8% to about 10% v/v, about 9% to about 11% v/v, about 10% to about 12% v/v, about 11% to about 12% v/v, about 10% to about 12% v/v, about 13% to about 15% v/v, about 12% to about 14% v/v, about 13% to about 15% v/v, about 14% to about 16% v/v, about 15% to about 17% v/v, about 16% to about 18% v/v, and about 17% to about 19% v/v. 
     
     
         44 . The composition of  claim 42 , wherein said amount of isopropyl alcohol is about 10% v/v. 
     
     
         45 . The composition of  claim 35 , wherein said build material comprises:
 an amount of alpha gypsum in a range of between about 65% to about 95% wt./wt.;   an amount of melamine formaldehyde resin in a range of between about 5% to about 10% wt./wt.; and   an amount of ammonium chloride in a range of between about 0.1% to about 1.0% wt./wt.   
     
     
         46 . The composition of  claim 45 , wherein said amount of alpha gypsum is selected from the group consisting of: about 70% to about 80% wt./wt., about 75% to about 85% wt./wt., and about 80% to about 90% wt./wt. 
     
     
         47 . The composition of  claim 45 , wherein said amount of melamine formaldehyde resin is selected from the group consisting of: about 6% to about 8% wt./wt. and about 7% to about 9% wt./wt. 
     
     
         48 . The composition of  claim 45 , wherein said amount of ammonium chloride is selected from the group consisting of: about 0.2% to about 0.4% wt./wt., about 0.3% to about 0.5% wt./wt., about 0.4% to about 0.6% wt./wt., about 0.5% to about 0.7% wt./wt., about 0.6% to about 0.8% wt./wt., and about 0.7% to about 0.9% wt./wt. 
     
     
         49 . The composition of  claim 45 , wherein said build material further comprises an amount of polyacrylic acid in a range of between about 2% to about 5% wt./wt. 
     
     
         50 . The composition of  claim 49 , wherein said amount of polyacrylic acid is selected from the group consisting of: about 2.5% to about 3.5% wt./wt., about 3.0% to about 4.0% wt./wt., and about 3.5% to about 4.5% wt./wt. 
     
     
         51 . The composition of  claim 45 , wherein said build material further comprises an amount of reinforcement elements in a range of between about 0.5% to about 5% wt./wt. 
     
     
         52 . The composition of  claim 51 , wherein said amount of reinforcement elements comprises one or more of said reinforcement elements selected from the group consisting of: glass balloons, glass microspheres, carbon nanotubes, glass fibers, and plastic fibers, clay nanotubes, and combinations thereof. 
     
     
         53 . The composition of  claim 45 , wherein said build material further comprises an amount of aluminum powder in a range of between about 0.5% to about 5% wt./wt. 
     
     
         54 . The composition of  claim 53 , wherein said build material further comprises an amount of carbon black in a range of between about 0.1% to about 5% wt./wt. 
     
     
         55 . The composition of  claim 45 , wherein said build material further comprises an amount of chop carbon fiber in a range of between about 0.5% to about 5% wt./wt. 
     
     
         56 . The composition of  claim 45 , wherein said build material further comprises an amount of microballoons in a range of between about 0.5% to about 2% wt./wt. 
     
     
         57 - 102 . (canceled)