System for printing three dimensional objects using a liquid-matrix support

Abstract

A system for printing three dimensional objects using a liquid-matrix support includes a motor, a resin, a stage, oil, and a light projecting source. The motor is an operating interface that is adapted to move the stage in an upward or in a downward direction. The resin in the system comprises a light polymerizable liquid. The light from the light projecting source is projected onto the resin to provide a shape to the three dimensional objects. The stage is adapted to move in the upward or in the downward direction to support the growing layers of the printed three dimensional objects. The oil is a non-aqueous hydrophobic and oleo-phobic component that is coupled at an interface with the resin by a liquid-matrix support which includes an additive. The light projecting irradiates the resin, and, in a preferred embodiment, irradiation passes through the oil to the resin. The liquid-matrix support enhances speed, resolution and provides smooth finishing texture to the printed three dimensional objects of large and small dimensions.

1 . A system for printing three dimensional objects using a liquid-matrix support, wherein the system comprises:
 a motor;   a resin;   a stage;   oil; and   a light projecting source,   wherein the motor is an operating interface that is adapted to move the stage in an upward or in a downward direction;   wherein the resin is a light polymerizable liquid, wherein a light from the light projecting source is projected on the resin so as to provide a shape to three dimensional objects;   wherein the stage is adapted to support growing layers of the three dimensional objects upon irradiation of light;   wherein the oil is a non-aqueous hydrophobic and oleo-phobic component,   wherein the oil is layered below the resin; and   wherein the liquid-matrix support is a liquid bi-layer formed from one or more additives.   
     
     
         2 . The system of  claim 1 , wherein the liquid-matrix support is created between the resin and the oil. 
     
     
         3 . The system of  claim 2 , wherein the oil functions as a liquid support for the resin, wherein the resin is selected from the group consisting of urethanes, epoxy and/or acrylates, and selected from a group of combinations of mono-acrylate, di-acrylate, tri-acrylate, tetra-acrylates, poly-acrylate, urethanes, poly-urethanes, epoxy with oligomers and additives,
 wherein the additives are in the resin and are represented by the formula
   Rf-X-R 
   where Rf is a perfluorinated alkyl group selected from the group consisting of CF 3 (CF 2 )n-, CF 3 (OCF 2 CF 2 )n-, CF 3 (OCF 2 CF 2 CF 2 )n-, and CF 2 [CF(CF 3 )—CF 2 —O]n- where n=1 to 30;   X is a chemical linkage having one or more ethers, esters, or amides between Rf and R, or is a single bond connecting Rf and R; and   R is a non-fluorinated alkyl, alkenyl, alkynyl, or aryl group with functional groups selected from the group consisting of such as are alcohols, amines, ethers, esters, and amides; and   wherein the oil is selected from group comprising of aliphatic and polymeric perfluorinated compounds represented as of CF 3 (CF 2 )n-, CF_(OCF 2 CF 2 )n-, CF 3 (OCF 2 CF 2 CF 2 )n-, and CF 2 [CF(CF 3 )—CF 2 —O]n- where n=10 to 100.   
     
     
         4 . The system of  claim 1 , wherein the oil is selected from a group consisting of perfluorodecalin, perfluoroperhydrophenanthrene, perfluoromethyldecalin, and perfluorperhydrobenzyltetralin. 
     
     
         5 . The system of  claim 1 , wherein the liquid-matrix support is adapted to decrease the surface tension of the resin in the printed three dimensional objects. 
     
     
         6 . The system of  claim 1 , wherein the liquid-matrix support is adapted to decrease interaction of printed three dimensional objects with the oil while the stage moves in the upward direction. 
     
     
         7 . The system of  claim 1 , wherein the liquid-matrix support is adapted to increase surface energy of the oil in order to increase wetting of the oil by the resin. 
     
     
         8 . The system of  claim 2 , wherein the additives work at the liquid-matrix support of the resin and the oil to provide a smooth texture to the printed three dimensional objects. 
     
     
         9 . The system of  claim 1 , wherein the system is configured to operate at a speed up to 20-30 mm/min for printing the three dimensional objects. 
     
     
         10 . A system for printing of three dimensional objects using a liquid-matrix support, wherein the system comprises:
 a motor that is an operating interface that is adapted to move a stage in one or more of an upward direction and a downward direction;   a resin that is a light polymerizable liquid;   one or more additives in the resin;   a light projecting source which is configured to project light on the resin to provide a shape to three dimensional objects created from polymerized resin;   a stage that is adapted to support the growing layers of the three dimensional objects;   oil that is a non-aqueous hydrophobic and oleo-phobic component,   wherein the oil is layered with the resin, wherein the oil is a liquid support for the resin;   wherein the liquid-matrix support is a liquid bi-layer formed from one or more additives;   wherein the resin comprises one or more of acrylates,   on urethanes, and epoxies; and   wherein the one or more additives in the resin are represented by the formula
   Rf-X-R 
   where Rf is a perfluorinated alkyl group selected from the group consisting of CF 3 (CF 2 )n-, CF 3 (OCF 2 CF 2 )n-, CF 3 (OCF 2 CF 2 CF 2 )n-, and CF 2 [CF(CF 3 )—CF 2 —O]n- where n=1 to 30;   where X is a linkage group containing one or more ethers, esters, or amides linking Rf and R, or is a single bond linking Rf and R; and   wherein R is a non-fluorinated alkyl, alkenyl, alkynyl, or aryl group with functional groups selected from alcohols, amines, ethers, esters, and amides.   
     
     
         11 . The system of  claim 10 , wherein the oil is selected from the group consisting of perfluorodecalin, perfluoroperhydrophenanthrene, perfluoromethyldecalin, and perfluorperhydrobenzyltetralin. 
     
     
         12 . The system of  claim 10 , wherein the liquid-matrix support is adapted to decrease the surface tension of the resin in printing the three dimensional objects. 
     
     
         13 . The system of  claim 10 , wherein the liquid-matrix support is adapted to decrease interaction of the printed three dimensional objects with the oil while the stage moves in the upward direction. 
     
     
         14 . The system of  claim 1 , wherein the liquid-matrix support is adapted to increase wetting of the oil with the resin. 
     
     
         15 . The system of  claim 10 , wherein the additives work at the liquid-matrix support of the resin and the oil to provide a smooth texture of the printed three dimensional objects. 
     
     
         16 - 19 . (canceled)