Additive manufacturing with dual precusor resins

Abstract

Apparatus for, and associated method of, making a three-dimensional object from a light polymerizable resin by inkjet additive manufacturing are described. The methods and apparatus employ dual precursor resins, including but not limited to dual cure resins having a first component photopolymerizable and a second component polymerizable by a mechanism different from the first component.

That which is claimed is: 
     
         1 . A method of making a three-dimensional object, comprising:
 (a) jetting droplets of at least one dual cure resin or precursor thereof through at least one nozzle carried by a print head of a three-dimensional printing apparatus to form a deposited dual cure resin portion, the dual cure resin comprising a first polymerizable component and a second polymerizable component, wherein said first component is photopolymerizable and said second component is polymerizable by a mechanism different from said first component;   (b) polymerizing said first component with light;   (c) repositioning said print head; and   (d) repeating steps (a) through (c) to form a newly deposited dual cure resin portion on or adjacent to a previously deposited dual cure resin portion until an intermediate three-dimensional object is formed; and   (e) curing said second component by the mechanism different from said first component to produce said three-dimensional object.   
     
     
         2 . The method of  claim 1 , wherein said dual cure resin is produced by providing first and second precursor resins, with said precursor resins being combined in a mixer, the mixer operatively connected to said at least one nozzle, to form said dual cure resin prior to jetting said resin from said nozzle. 
     
     
         3 . The method of  claim 2 , wherein one of said precursor resins comprises an unblocked polyisocyanate, and the other of said precursor resins comprises a polyol, a polyamine, or a combination thereof. 
     
     
         4 . The method of  claim 1 , wherein said at least one dual cure resin or precursor thereof is heated prior to said jetting step to reduce the viscosity thereof. 
     
     
         5 . The method of  claim 1 , wherein said at least one dual cure resin or precursor thereof comprises a solvent in an amount effective to reduce the viscosity thereof during said jetting step. 
     
     
         6 . The method according to  claim 5 , wherein at least a portion of said solvent evaporates from said droplets prior to said droplets forming said deposited dual cure resin portion. 
     
     
         7 . The method of  claim 1 , wherein said first component is included in said resin in an amount of not more than 10 percent by weight. 
     
     
         8 . The method of  claim 1 , wherein:
 (i) at least two different dual cure resins or precursors thereof that generate finished objects of different tensile properties are provided through separate orifices; and   (ii) said jetting step includes selectively jetting said at least two different dual cure resins or precursors thereof in a patterned manner to form a three-dimensional object having different tensile properties in different portions thereof.   
     
     
         9 . The method of  claim 1 , wherein said second component comprises a precursor to a polyurethane, polyurea, epoxy polymer, cyanate ester polymer, silicone polymer, or combination thereof. 
     
     
         10 . The method of  claim 1 , wherein said curing step (e) is carried out after forming said three-dimensional object. 
     
     
         11 . An apparatus for producing a three-dimensional object by additive manufacturing, comprising:
 (a) a printing head having at least a first nozzle and a second nozzle through which precursor resins can be jetted;   (b) a build platform on which a three-dimensional object can be formed by successive deposition of deposited resin portions from said precursor resins after jetting;   (c) a positioning apparatus operatively associated with said printing head and said build platform;   (d) a first precursor resin supply operatively associated with said first nozzle; and   (e) a second precursor resin supply operatively associated with said second nozzle;   wherein said first nozzle and said second nozzle are configured to combine said first and second precursor resins after being jetted and produce a complete resin prior to or upon forming said deposited resin portions.   
     
     
         12 . The apparatus of  claim 11 , further comprising:
 (f) a light source operatively associated with said build platform and configured to photopolymerize said deposited resin portions.   
     
     
         13 . A method of making a three-dimensional object, comprising:
 (a) concurrently jetting droplets of a first precursor resin and a second precursor resin through separate nozzles, the nozzles carried by the same print head of a three-dimentional printing apparatus, the nozzles configured to combine said first and second precursor resins after jetting and produce a complete resin prior to or upon forming a deposited resin portion;   (b) optionally photopolymerizing said deposited resin portion;   (c) repositioning said print head; and   (d) repeating steps (a) through (c) to form a newly deposited resin portion on or adjacent to a previously deposited resin portion, until said three-dimensional object is formed.   
     
     
         14 . The method of  claim 13 , wherein said complete resin comprises a dual cure resin, and said photopolymerizing step (b) is included. 
     
     
         15 . The method of  claim 13 , wherein one of said precursor resins comprises an unblocked polyisocyanate, and the other of said precursor resins comprises a polyol, a polyamine, or a combination thereof. 
     
     
         16 . The method of  claim 13 , wherein one or both of said precursor resins is heated prior to said jetting step to reduce the viscosity thereof. 
     
     
         17 . The method of  claim 13 , wherein one or both of said precursor resins comprises a solvent in an amount effective to reduce the viscosity thereof during said jetting step. 
     
     
         18 . The method according to  claim 17 , wherein at least a portion of said solvent evaporates from said droplets prior to said droplets forming said deposited resin portion.