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Title:
COMPOSITIONS FOR REMOVING SUPPORT MATERIAL FROM A 3-D PRINTED OBJECT AND METHODS OF MAKING AND USING SAME
Document Type and Number:
WIPO Patent Application WO/2019/203855
Kind Code:
A1
Abstract:
Described are aqueous finishing solutions for removing unwanted support material from a 3D-printed object, such as an object produced by Polyjet or FDM techniques. The compositions have a base, an optional filler, an optional first caustic agent, an optional second caustic agent, a glycol ether, an antifoaming agent, and water. Also described are methods of using the finishing solutions.

Inventors:
FARFAGLIA MARC (US)
GRANT CASSIDY (US)
HUTCHINSON DANIEL (US)
BLOOD JEFF (US)
Application Number:
PCT/US2018/028685
Publication Date:
October 24, 2019
Filing Date:
April 20, 2018
Export Citation:
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Assignee:
POSTPROCESS TECH INC (US)
FARFAGLIA MARC (US)
GRANT CASSIDY (US)
International Classes:
C04B35/04; C04B35/63; C04B35/634
Foreign References:
US5401325A1995-03-28
US20110186081A12011-08-04
US20160263839A12016-09-15
US6790403B12004-09-14
Other References:
"How to Remove SUP706 Soluble Support on a 3D Printed Part", GRABCAD COMMUNITY, 28 July 2017 (2017-07-28), XP055649251, Retrieved from the Internet [retrieved on 20180626]
WU, THE CHEMISTRY BEHIND SOLUBLE SUPPORT REMOVAL IN FUSED DEPOSITION MODELING, 7 November 2016 (2016-11-07), pages 1 - 4, XP055649261, Retrieved from the Internet [retrieved on 20180626]
"Trans-280- Silicone-Free Defoamer", DIRECT N-PAKT, 2000, pages 1, Retrieved from the Internet [retrieved on 20180626]
Attorney, Agent or Firm:
ROBERTS, Kent, R. et al. (US)
Download PDF:
Claims:
CLAIMS;

1. A finishing solution for removing support material from an object comprising:

0.01-25% by weight an aqueous base;

optionally. 0.0005-2.5% by weight a filler;

optionally, 0.0005 -2.5% by weight a first caustic agent;

optionally, 0.0005 -2.5% by weight a second caustic agent;

0.35-49.5% by weight a glycol ether; and

0,005-15% by weight an ant oaming agent; and

water.

2, The finishing solution of claim. 1, wherein the aqueous base comprises 1 to 50% by weight a base. 3. The finishing solution of claim 2, -wherein the base is selected from the group consisting of lithium hydroxide, sodium hydroxide, potassium hydroxide, rubidium hydroxide, cesiu hydroxide, magnesium hydroxide, calcium hydroxide, strontium hydroxide, barium hydroxide, and combinations thereof. 4. The finishing solution of claim 1, wherein the filler is sodium sulfate.

5, The finishing solution of clai 1, wherein the first caustic agent is selected from the group consisting of potassium bicarbonate, sodium bicarbonate, and combinations thereof

6. The finishing solution of claim 1, wherein the secon caustic agent is selected from the group consisting of potassium carbonate, .sodium carbonate, and combinations thereof.

7. The finishing solution of claim 1, wherein the glycol ether is selected from the group consisting ofmethoxytriglycol, eihox triglyeoi, butoxytriglycol, diethylene glycol n-butyl ether acetate, diethylene glycol monobutyl ether, ethylene glycol n-butyl ether acetate, ethylene glycol monobutyl ether, diethylene glycol monoethyl ether, DOWANOL 5 i DPH 255, ethylene glycol phenyl ether, diethyiene glycol monohexyl ether, ethylene glycol monohexyl ether, diethyiene glycol monomethyl ether, ethylene glycol monopropyl ether, di (propylene glycol) methyl ether, di ropylene glycol methyl ether acetate, ch ropylene glycol n-buiy! ether, propylene glycol diacetate, propylene glycol methyl ether, propylene glycol raonomethyi ether acetate, propylene glycol n-butyl ether, propylene glycol phenyl ether, tripropylene glycol methyl ether, tripropylene glycol n-butyl ether, dipropylene glycol dimethyl ether, 2-butoxyethanol, an combinations thereof

8. The finishing solution of claim I , wherein the antifoaming agent is Trans 280.

9. The finishing solution of claim I, wherein the support material resulted from a Polyjet printing process.

10. The finishing solution of claim 9, wherein the support comprises SUP705, SUP706, SUP708, or a combination thereof.

1 1. The finishing solution of claim 1» wherein:

the base is 45% by weight aqueous potassium hydroxide;

the filler is sodium sulfate;

the first caustic agent is sodium bicarbonate;

the second caustic agent is potassium carbonate;

the glycol ether is 2-hutoxyethanol;

the antifoaming agent is Trans 280.

1 . The finishing solution of clai 1, wherein the support material resulted from a fused deposition modeling (FDIV1) printing process.

13, The finishing solution of claim 12, wherein the support material comprises SR20, SR30, SRI 00, SRI 10, or a combination thereof.

14. The finishing solution of claim 1, wherein:

the base is 45% by weight aqueous potassiu hydroxide;

the filler is sodium sulfate;

the first caustic agent is sodium bicarbonate;

the second caustic agent is potassium carbonate;

the glycol ether is di(propylene glycol) methyl ether; and

the anti foaming agent is Trans 280. IS. The finishing solution of claim 1 , wherein components of the finishing solution are separated as Component A, Component B, and water, wherein:

Component A comprises:

the aqueous base,

the filler,

the first caustic agent,

the second caustic agent, and

water;

Component B comprises:

the glycol ether, and

the antifoaming agent.

16. The finishing solution of claim 15, comprising:

1-20% volume Component A. wherein Component A comprises:

20-60% by weight an aqueous base,

0.05-5% by weight a filler,

0.05-5% by weight a first caustic agent,

0,05-5% by weight a second caustic agent, and

water.

1-10% volume Component B; wherein Component B comprises:

70-99% by weight a glycol ether, and

an antifoa ing agent.

17. The finishing solution of claim 16, comprising:

2% by volume Component A , comprising

50% by weight 45% by weight aqueous potassium hydroxide,

1% by weight sodium sulfate,

0.10% by weight sodium bicarbonate,

0,10% by weight potassium carbonate, and

48.80 % by weight water; and

1% by volume Component B, comprising:

95% by weight 2-butoxy ethanol, and

5% by weight Trans 280.

18. The finishing solution of claim 16, comprising:

4% by volume Component A, comprising

50% by weight 45% by weight aqueous potassium hydroxide, 1 % by weight sodium sulfate,

0.10% by weight sodium bicarbonate,

0.10% by weight potassium carbonate, and

48.80% by weight water; and

i% by volume Component B, comprising:

95% by weight di(propyiene glycol) methyl ether, and

5% bv weiaht Trans 280

19. A method of removing support material from an object comprising:

i) applying finishing solution whereby the support material is remo ved from the object, wherein the finishing solution comprises:

0.01- 25% by weight an aqueous base;

optionally, 0.0005-2.5% by weight a filler;

optionally, 0.0005 -2.5% by weight a first caustic agent;

optionally, 0.0005 -2.5% by weight a second caustic agent;

0.35-49.5% by weight a glycol ether; and

0.005-15% by weight an antiioaming agent; and

water; and

ii) removing the finishing solution from the object.

20. The method of claim 19, further comprising heating the finishing solution.

21. The metho of claim 20, wherein the support material is removed from an object made by a Polyjet printing process and the finishing solution is heated to 90-125 *F.

22. The method of claim 20, wherein the support material is remove from an object made by an FDM printing process and the finishing solution is heated to 120 -130 °F.

23. The method of claim 19, wherein the finishing solution is applied at a pressure of 1-40 pst.

24. The method of claim 19, wherein prior to forming the finishing solution, the finishing solution components are separated as Component A, Component B, and water, wherein:

Component A comprises:

the aqueous base,

the filler,

the first caustic agent,

the second caustic agent, and

water;

Component B comprises:

the ulvcol ether and

the antifoaming agent.

25. The method of claim 19, wherein the finishing solution is formed by combining:

2% by volume Component A, comprising

50% by weight 45% by weight aqueous potassium hydroxide,

1% by weight sodium sulfate,

0.10% by weight sodium bicarbonate,

0.10% by weight potassium carbonate, and

48.80 % by weight water; and

1% by volume Component B, comprising:

95% by weight 2-butoxyethanoL and

5% by weight Trans 280. 26. The metho of claim 19, wherein the finishing solution Is formed by combining;

4% by volume Component A, comprising

50% by weight 45% by weight aqueous potassium hydroxide,

.1% by weight sodium sulfate,

0.10% by weight sodium bicarbonate,

0.10% by weight potassium carbonate, and

48.80 % bv weight water; and

1 % by volume Component B. comprising:

95% by weight di (propylene glycol) methyl ether, and

5% by weight Trans 280.

Description:
COMPOSITION'S FOR REMOVING SUPPORT MATERIAL FROM: A 3D-PRINTED OBJECT AND METHODS OF MAKING AND USING SAME

FIELD OF THE DISCLOSURE

10001] This disclosure relates generally to fluidic solutions for removing unwanted support material from objects made by additive manufacturing techniques such as 3D printing, and, more specifically, to fluidic solutions and methods for removing support material by spraying the object with the solution,

BACKGROUND Of THE DISCLOSURE

[0002| 3-D printing is a process whereby a computer controlled device (e.g., a printer) creates an object through additive manufacturing. That is, an object is“printed,” for example, using an inkjet printer head that additively deposits materia! in such a way that an object is created (printed) fro the starting platform (a“printing tray 5' or a“build tray 5 ). The additive manufacturing methods that are commonly used require additional material

(“support material”) to be printed for the purpose of supporting portions of the object during printing. This support material buttresses the object to prevent issues like sagging. As used herein, unless otherwise indicated, the term“finishing” refers to removing unwanted materia! from a 3D-printed object so as to produce a finished part, Finishing can include one or more processes, including, but not limited to, removing unwanted metal powder, removing unwanted print material, and/or removing unwanted support material. In the 3-D printing industry, finishing may be referred to as“cleaning.’ 5

[0003] The support material can have a complex geometry and can also be extensive because it may support the object at a plurality of locations. Additionally, because additive manufacturing prints an object in discrete layers, the surface finish of a 3D-printed object is rough since edges of the layers do not always align with each other, thus creating a rough, bumpy outer surface. This outer surface is not only unappealing from a visual standpoint, but also can create stress concentrations, which could result in cracks during testing or use of the object and thus lead to a premature failure.

[0004] Some finishing solutions are organic based and contain isopropanol (IP A), which has a low flash point, making it dangerous to work with.

[0005] T here is a long felt need for a finishing solution that is primarily aqueous, and thus less toxic and less flammable. SUMMARY OF THE DISCLOSURE

(0006} in this document we focus on finishing solutions and methods of using same that are targeted at removing unwanted support material

|O®07| The present disclosure describes a finishing solution for removing support material A finishing solution that is in keeping with the invention may comprise:

(a) 0.1-23% by weight an aqueous base, including all 0.0001% values and ranges

therebetween;

(b) optionally, 0.0005-2.5% by weight a filler, including all 0.0001% values and ranges therebetween;

(c) optionally, 0.0005-2.5% by weight a first caustic agent, including all 0.0001% values and ranges therebetween;

fd) optionally, 0.0005-2.5% by weight a second caustic agent, including all 0.0001% values and ranges therebetween;

(e) 0.35-49.5% by weight a glycol ether, including all 0.0001% values and ranges

therebetween;

(1) 0.005 -15% by weight an antlfoaming agent, including ail 0.0001 % values and ranges therebetween; and

(g) water (e.g., the remainder of this finishing solution is water).

10008} The present disclosure describes a finishing solution for removing support material A finishing solution that is in keeping with the invention may comprise:

(a) 1.-20% by volume Component A, including all 0J% values and ranges therebetween;

(b) 1-10% by volume Component B, including all 0.1% values and ranges therebetween; and

(c) water (e.g., the remai nder of this finishing solu tion is water).

Component A may comprise:

(a) 20-60% by weight an aqueous base, including ail 0.1% values and ranges

therebetween;

(b) optionally, 0-5% by weight a filler, including all 0.1% values and ranges

therebetween;

(c) optionally, 0-5% by weight a first caustic agent, including all 0.1% values and ranges therebetween;

(d) optionally, 0-5% by weight a second caustic agent, including all 0.1% values and ranges therebetween; and

(e) water (e.g., the remainder of Component A is water). Component B may comprise:

(a) 70-99% by weight a glycol ether; including all 0, 1% values and ranges therebetween; and

(b) an antifoamirig agent (e.g., the remainder of Component B is an antifoaming agent), (0009] Alternatively, a finishing solution that is in keeping with the Invention may comprise:

(a) 66-99% by volume Component A: and

(b) the remainder is Component B.

(99101 A finishing solution that is in keeping with the invention can finish (e.g., remove support material from) a 1>printed object produced through, for example, Polyjet techniques or FDM techniques. Without intending to be bound to any particular theory, It Is expected tha t different glycol ethers affect the abili ty of the finishing solution to finish different types of materials. For example, using a particular glycol ether (e.g., 2- butoxyethanoi ( ΈB"}) in Component B may produce a finishing solution that is well suited for finishing Polyjet 3D-printed objects. And, by using a different particular glycol ether (e.g., di(propylene glycol ff DP!vT)) in Component B, a finishing solution that is well suited for finishing FDM 3D-printed objects may be obtained,

{9911) The invention may be embodied as a method of using a finishing solution such as those describe above. The method can comprise:

(a) mixing Component A, Component B, and water, such that a finishing solution is formed;

(b) applying the finishing solution to a 3D -printed object (e.g , spraying and/or

submerging 3D-printed object).

BRIEF DESCRIPTION OF THE FIGURES

]09ί2) For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying figures.

{00.13) Figure 1 A and Figure IB are each a photo of a fused deposition modeling

(“FDM”) 3D~printed object (a phone case) prior to finishing. Figure 1 A shows the front side of the object, and Figure IB shows the backside of the object. Figure 1 C and Figure I D are each a photo of that same object after applying a finishing solution that is in keeping with the invention. Figure 1C show's the front side of the object, and Figure I D shows tire backside of the object. Figure 2A and Figure 2B are each a photo of an unfinished FDM 3D-printed object. Figure 2 A shows the front side of the object, and Figure 2B shows the backside of the object. Figure 2€ and 2D are each a photo of the same 3D-printed object after applying a finishing solution that is in keeping with the invention. Figure 2C and Figure 2D are each a photo of that same object after applying a finishing solution that is in keeping with the invention.

0015 j Figure 3 is a schematic of a machine that sprays a finishi ng sol ut ion on a 3D- printed object. The numbers in Figure 3 identify a water Input line (1 ), a first volumetric dispenser (2), a Component A container (3), a second volumetric dispenser (4), a Component B container (5), a total solution input line (6), a pump (7), valves (8), upper spray nozzles (9), lower spray nozzles ( 10), a heater (1 1), a tank (12), a support tray (14), and a machine housing (15).

10016] f igure 4 shows a flow diagram of a method using a finishing solution that Is in keeping with the invention.

DETAILED DESCRIPTION OF THE DISCLOSURE

[00171 Although claimed subject matter will be described In terms of certain embodiments, other embodiments, incl udi ng embodiments that do not provide all of the benefits and features set forth herein, are also within the scope of this invention. Various changes to the structure and/or method may be made without departing from the scope of th invention.

[00181 Ranges of values are disclosed herein. The ranges set out a lower limit value

(“LLV”) and an upper limit value (“ULV”). The LEV, ULY, and all values between the LLV and ULV are part of the range.

f0019] The present disclosure describes finishing solutions for removing support material tram a FDM and/or Polyjet 3D-pri.nted object. Support material of an unfinished object is dissolved by a finishing solution that is in keeping with the invention to provide a finished object.

[0020] As used herein, unless otherwise indicated, the term“support material” refers to material that is operatively arranged to support portions of an object during an additive manufacturing process, but which are unwanted once the manufacturing process is complete. Support material can comprise the same material as the object which i being manufactured, or can be made of a different material. Materials that can be removed during finishing include, but are not limited to, materials used during Polyjet 3D printing (e.g., SUP705, SUF706, SUP707, SUP708, and combinations thereof) and/or PDM 3D printing (e.g.. SR2C), SR30, SR 100, SR 110, and combinations thereof).

(0021 ] Some finishing processes are mechanical in nature (e.g,, abrasion techniques, such as sanding), and others are a combination of mechanical processe and chemical processes, Chemical finishing solutions may be caustic. In a conventional machine that uses chemical finishing solutions to remove support material, an unfinished 3D-printed object may be subjected to a process to remove unwanted support material, and thereby provide a finished object in one such process, the unfinished object is placed (e.g , partially or completely submerged) in a tank that has been filled (e.g., at least partially filled) with a liquid finishing solution. While In the finishing solution, the object may be subjected to mechanical agitation, abrasion, and/or heating in order to remove support material from the object. Mechanical agitation may occur by moving the liquid .finishing solution (e.g., via a pump) and/or by using ultrasound. In other such processes, the object is subjected to a liquid spray. In those processes, the object is placed in a chamber, and a pump is used to force the liquid finishing solution through one or more nozzles, which both apply the finishing solution to the object and mechanically agitates the object in both such processes, the liquid may include chemical solvents to dissolve support material, and thereby create a finished or nearly finished form of the object bleat from a heat source may be used to maintain the finishing solution at a desired temperature. Die support material may be removed thermally, chemically, mechanical ly or via a combination of two or more of these general processes.

[0022) A finishing solution that is In keeping with the invention may be a finishing solution for removing support material. The finishing solution may comprise:

(a) 0.1-25% by weight an aqueous base, including all 0.0001% values and ranges

therebetween;

(b) optionally, 0.0005 -2.5% by weight a filler, including all 0.0001 values and ranges therebetween;

(c) optionally, 0.0005-2.5% by weight a first caustic agent, including all 0.0001% values and ranges therebetween;

(d) optionally, 0.0005-2.5% by weight a second caustic agent, including all 0.0001% values and ranges therebetween;

(e) 0.35-49.5% by weight a glycol ether, including all 0.0001% values and ranges

therebetween;

(f) 0.005-15% by weight an antifoaming agent, including all 0.0001% values and ranges therebetween ; and (g) water (e.g.. the remainder of this finishing solution is water).

[0023] A finishing solution that is in keeping with the invention may be a single solution, or, alternatively, may be a combination of solutions (e.g., neat or diluted with water) that are mixed together to provide a finishing solution.

[0024] A finishing solution that is In keeping with the invention may be a finishing solution for removing support material. The finishing solution may comprise:

1 -20% by volume Component A, including all 0,1% values and ranges therebetween; 1-10% by volume Component B, including all 0.1% values and ranges therebetween; and water (e.g.. the remainder of this finishing solution is water),

Component A may comprise:

(a) 20-60% by weight an aqueous base, including ail 0.1% values and ranges

therebetween;

(b) optionally, 0-5% by weight a filler, including all 0.1% values and ranges

therebetween;

(c) optionally, 0-5% by weight a first caustic agent, including all 0.1 % values and ranges therebetween;

(d) optionally, 0-5% by weight a second caustic agent. Including all 0.1% values and ranges therebetween; and

(e) water (e.g., the remainder of Component A is water).

Component B may comprise:

(a) 70-99% by weight a glycol ether, including all 0.1% values and ranges

therebetween; and

(b) an antifoaming agent (e.g., the remainder of Component B is an antifoaming

agent).

[0025] Alternatively, a finishing solution that is in keeping with the invention may comprise:

(a) 1-99% by volume Component A; and

(b) the remainder is Component B.

[0026] A finishing solution that is in keeping with the invention may be able to finish (e.g., remove support material) 3D-printed objects produced, for example, through Polyjet techniques, FDM techniques, or combinations thereof. Without intending to be boun to any particular theory, it is expected that different glycol ethers affect the abilit of the finishing solution to finish different types of materials. For example, using a particular glycol ether (e.g., 2-butoxyethanol (‘TIB’}) in Component B may produce a finishing solution that is well suited for finishing Polyjet 3D-printed objects. And, by using a different particular glycol ether (e.g., di (propylene glycol (“DPM”)) in Component B, a finishing solution that is well suited for finishing FDM 3D-printed objects may be obtained.

[0027] An aqueous base ma be used to provide a desired pH (e.g., a pH of 10 or greater) of the finishing sol u tion. Non-limiting examples of suitable aqueous bases include hydroxide bases, such as I,ίOH, NaOH, KOH, RbOH, CsOH, Mg(OH)¾ Ca(OH) 2 , $r(OH) 2 BatOHp, and combinations thereof. An aqueous base suitable for tire invention may be a 1- 50% by weight aqueous solution. In a preferred example, the base is a 45% by weight aqueous solution (e.g., such as a potassium hydroxide solution (45 wt. % KOH in ¾()) sold by Sigma Aldrich). For example, a finishing solution that is in keeping with invention may be 0.1-25% b weight an aqueous base, including ail 0.0001 % values and ranges therebetween, relative to the total weight of the finishing solution,

[0028] A filler may be present in finishing solution that is in beeping with the invention. Fillers are inexpensive components which have little or no impact on the function of the finishing solution, except to provide sufficient volume to, for example, fill a tank in a machine that is confi ured for finishing a 3D-printed object Fillers may be, but are not limited to, sodium salts and sulfate salts. In an example, the filler in a finishing solution may be sodium sulfate. For example, a finishing solution that is in keeping with invention optionally may be 0.0005-2.5% by weight a filler, including all 0.0001 % values and ranges therebetween, relative to the total weight of the finishing solution.

[0029] A first caustic agent may be present in a finishing solution that is in keeping with the invention. he caustic agent may be used to provide a desired phi the pH (e.g., a pH of .10 or greater) of the finishing solution. Examples of a first caustic agent include, but are not limited to, potassium bicarbonate, sodium bicarbonate, potassium carbonate, sodium carbonate, and the like. For example, a finishing solution that is in keeping with invention optionally may be 0.0005-2.5% by weight a first caustic agent, including all 0.0001% values and ranges therebetween, relative to the total weight of the finishing solution.

[0030] A second caustic agent may optionally be present in a finishing solution that is in keeping with the invention. The caustic agent may be used to provide a desired pH the pH (e.g., a pH of 10 or greater) of the finishing solution. Examples of a second caustic agent include, but are not limited to, potassium bicarbonate, sodium bicarbonate, potassium carbonate, sodium carbonate, and the like. If there are first and second caustic agents, then the first and second caustic agents can optionally be conjugate aeids/bases of each other (e.g., HCO.fi and COr ). For example, a finishing solution that is in keeping with invention optionally may be 0.0005 -2.5% by weight a second caustic agent, including all 0.0001% values and ranges therebet ween, relati ve to the total weight of the finishing solution.

{0031] A glycol ether in a finishing solution that is in keeping with the invention may aid in dissolving organic materials and the Like found in resins and support materials frequently used in Polyjet and/or FDM printing techniques. Examples of glycol ethers suitable lor a finishing solution that is In keeping with the invention may include, but are not limited to, methoxytrigiycol, ethoxytriglyeol, binoxytri glycol diethylene glycol n-butyl ether acetate, diethylene glycol monobutyl ether, ethylene glycol n-butyl ether acetate, ethylene glycol monobutyl ether, diethylene glycol monoethyl ether, DOWA OL l 5 DPI ! 255, ethylene glycol phenyl ether, diethyiene glycol monohexyi ether, ethylene glycol onobex l ether, diethyiene glycol monomeihyl ether, ethylene glycol monopropyl ether, di(propylenc glycol) methyl ether, dipropylene glycol methyl ether acetate, dipropylene glycol n-butyl ether, propylene glycol diacetate, propylene glycol methyl ether, propylene glycol

monomethyl ether acetate, propylene glycol n-butyl ether, propylene glycol phenyl ether, tripropylene glycol methyl ether, tripropylene glycol n-butyl ether, dipropylene glycol dimethyl ether. 2-butoxyetlianok and combinations thereof. For example, a finishing solution that is in keeping with invention may be 0.35-49.5% by weight a glycol ether, including all 0.0001% values and ranges therebetween, relative to the total weight of the finishing solution.

A finishing solution according to the invention may include an antifoaming agent (also referred to as a“defoamer” or“defoammg agent”). Such an antifoaming agent may be nsed to reduce foaming of the finishing solution. An example of an anti foaming agent that may be suitable is Trans 280, which is available from Applied Material Solutions, Inc., located in Elkhom, WI 53121. For example, a finishing solution that is In keeping with invention may be 0.005 -15% by weight a first caustic agent including all 0.0001% values and ranges therebetween, relative to the total weight of the finishing solution.

[0033] A particular example of a finishing solution that is in keeping with the invention comprises:

(a) 1 -20% by volume Component A, including all 0.1% values and ranges therebetween;

(b) 1-10% by volume Component B, including all 0.1 % values and ranges therebetween: and

(c) water (e,g., the remainder of this finishing solution is water).

Component A has:

(a) 20-60% by weight, includ ing all 0.1 % values and ranges therebetween, 45% by weigh aqueous KOH; (h) optionally, 0-5% by weight sodium sulfate, including all 0.1% values and ranges therebetween;

(c) optionally, 0-5% by weight sodium bicarbonate, including ail 0.1% values and ranges therebetween;

(d) optionally, 0-5% by weight potassium carbonate, including all 0.1% values and ranees therebetween; and

(e) water (e.g,. the remainder of Component A is water).

Component B has;

(a) 70-99% by weight 2-btttoxyefhanol (“EB M ), including ail 0.1% values and ranges therebetween; and

(b) Trans 280 (e.g., the remainder of Component B is Trans 280)

n such an example, it is expected that the finishing solution is well suited for finishing (e.g., remove support material) Polyjet 3 D~printed objects.

[0034] In a particular example, finishing solution for finishing (e.g., remove support material) a Poiyjet 3D- printed objec has:

(a) 2% by volume Component A;

(b) 1% by volume Component B; and

(c) the remainder is water.

Component A has;

(a) 50% by weight 45% by weight aqueous KGH,;

(b) 1% by weight sodium sulfate;

(c) 0,1% by weight sodium bicarbonate;

(d) 0.1% by weight potassium carbonate; an

(e) the remainder is water.

Component B has:

(a) 95% by weight 2-butoxyethanoI f ΈB”); and

(b) the remainder is Trans 280.

[0035] Another example of a finishing solution that is in keeping with the invention, and which may be well suited for finishing (e.g., remove support material from) FDM 3D- printed objects has:

(a) 1-20% by volume Component A, including ail 0.1% values and ranges therebetween;

(b) 1-10% by volume Component B, including all 0.1% values and ranges therebetween; and

(c) water (e.g., the remainder of this finishing solution is water). Component A has:

(a) 20-60% by weight, including all 0.1% values and ranges therebetween, 45% by weight aqueous KOH,;

(b) optionally, 0-5% by weight sodiu sulfate, including all 0.1% values and ranges therebetween;

(c) optionally, 0-5% by weight sodium bicarbonate, including all 0.1% values and ranges therebetween;

td) optionally, 0 -5% by weight potassium carbonate, including all 0.1% values and ranges therebetween; and

(e) water (e.g., the remainder of Component A is water).

Component R has:

(a) 70-99% by weight di(propylene glycol) methyl ether including all 0 1% values and ranges therebetween; and

(b) Trans 280 (e.g., the remainder of Component R is water).

In a yet another example of a finishing solution that is in keeping with the invention, and which may be well suited for finishing (e.g., remove support material) FDM 3D-printed objects, the finishing solution may have:

(a) 4% by volume Component A;

(b) 1 % by volume Component B; and

(c) the remainder is water.

Component A. has;

(a) 50% by weight 45% by weight aqueous Ofb;

(b) 1% by weight sodium sulfate;

(c) 0.1% by weight sodium bicarbonate;

(d) 0 1% by weight potassium carbonate; and

(e) the remainder is water.

Component B has:

(a) 95% by weight difpropy!ene glycol) methyl ether (“DPM”); and

(b) the remainder is ' brans 280.

[0037] The invention may be embodied as a method of using a finishing solution. The steps of such a method may be sufficient to remove support material from a 3D-printed object. The method can comprise:

(a) mixing Component A, Component B, and water, such that a finishing solution that is in keeping with the invention may be formed; and (h) applying the finishing solution (e.g., spraying anchor submerging) to a 3D-printed object.

For example. Component A (which already has water in it). Component B, and water may be each in separate containers, and item those containers Component A and Component B may be dosed Into the water at a percent-by-volume rate, such that the amount of Component A by volume is I -20%, including ail 0.1% values and ranges therebetween, and Component B by volume is 1-10%, including ail 0.1 % values and ranges therebetween. Such dosing of Component A and Component B may continue until a desired volume of the finishing solution is obtained. The finishing solution is then applied (e.g., sprayed) on a 3D object to remove unwanted support material. The operator may determine finishing is complete upon a visual inspection of the part.

(0038] In another method, Component A and Component B are mixed. Following mixing, the mixture of Component A and Component B is then further mixed with water in yet another method, Component A and Component B can be combined with each other, without adding water. In such a combination, Component A may be 66-99% by volume, including all 0.1% values and ranges therebetween, and Component B may be 1-34% by volume, including all 0.1 % values and ranges therebetween. The finishing solution is then applied on a 3D object (e.g., the object is submerged in a finishing solution or the object is sprayed with a finishing solution) to remove unwanted support material. The operator may determine finishing 1s complete up by making a visual inspection of the pari.

(0039] Applying the finishing solution to an object may involve spraying, submerging, or otherwise contacting the 30-printed object with a finishing solution that is in keeping with the invention. It should be noted that when described herein, submersion of the object includes partially or completely submerging the object In the finishing solution.

(0040] Such an appl ication process may be carrie out by initially heating the finishing solution to a desired temperature (e.g., 90-140 °P. including all 0.1 °F values and ranges therebetween), and then spraying the finishin solution on the object, or submerging the object in the finishing solution. Heating the finishing solution can be achieved by using a heater or by heating the chamber or tank where the finishing solution is being applied or heating the tank in which the finishing solution is stored prior to pumping. For example, if the object is being sprayed, the chamber or tank in which the spraying occurs may be heated, or if the object is being submerged, a heating element may be place in the chamber where finishing is occurring {00 J ] In one embodiment of the invention a finishing solution comprises

Component A and Component B, where Component A is 66-99% by volume, including all 0.1% values and ranges therebetween, and the remainder is Component B. in such an example, a 3D -printed object can be submerged in said finishing solution.

{0042} in an example, the 3D-printed object can be sprayed with a finishing solution that is in keeping with the invention. Prior to spraying, the finishing solution can be stored in a container (e.g., tank (12)). A pump (7) that is fluidly connected to the tank (12), may be activated to move finishing solution from the tank (12) and pressurize the finishing solution up to a desired pressure, such as 1--40 psi, including all 0.1 psi values and ranges

therebetween. In a preferred example, the pressure is 30-40 psi (e.g., 35 psi). The pumped finishing solution leaves the pump (7) and passes through at least one valve (8B) that may he use to control the flow of finishing solution to at least one spray nozzle (9) that is oriented in such a way that the finishing solution is applie (e.g., sprayed on/at) to a 3D-printed object or portion thereof. Finishing solution that does not contact the 3D-printed object or portion thereof and/or finishing solution that is applied to the 3D~pfinted object or portion thereof and is running off (e.g., dripping off) the object may be collected. The collected finishing solution cun be cycled through the pump (7) and resprayed on/at the 3D~printed object or portion thereof.

[0043] In an example, when a finishing solution comprises Component A, as described herein, and Component B, as described herein, where Component A is 1-99% by volume, including all 0.1% values and ranges there between, and the remainder is Component B, the finishing solution can be sprayed onto a 3D-printed object at lower pressure (e.g., less than 10 psi). In this example, lower pressure may be used because the finishing solution is more caustic, thus the finishing solution can dissolve unwanted support material with less mechanical force (e.g., a force applie to the object fro being sprayed) than a less caustic solution. However, it should be noted that a highly caustic finishing solution can be sprayed at higher pressure (e.g., 10-40 psi, including all 0.1 psi values and ranges therebetween). [O044J In a particular method of using a finishing solution that is in keeping with the invention;

(i) Component A an Component B are arranged in separate containers (e.g., (3) an (5) in Figure 3), each having its own volumetric chemical dispenser (2) and (4) (e.g., a DOSATRON ® ), where each volumetric chemical dispenser is arranged in series with a water input line ( 1 ). For example, Figure 3 shows a water input line (1 ) is connected to the first volumetric chemical dispenser (2), with water entering volumetric chemical dispenser (2) of Component A first.

(ii) The water enters the Component A volumetric chemical dispenser (2) an is dosed (e.g., mixed) with Component A at a desired percent by volume rate.

(Hi) The water/Component A solution then enters the Component B volumetric chemical dispenser (4) an is dosed (e.g,, mixed) with Component B at a desired percent by volume rate, thus forming the finishing solution.

(iv> The finishing solution then enters a holding tank ( 12) until the tank (12) holds a

desired volume.

(v) A heater (11) may he arranged within the tank (12) to heat the finishing solution to a desired temperature (e.g., heat to a te erature of 90- 140 °F) during application (e.g,, spraying).

(vi) A pump (7) is fluidly connected to the tank (12) and when acti vated, the pump (7) moves fluid from the tank (12) and raises the pressure of the fluid. The discharge pressure of the pump (7) can be a pressure from 1 to 35 psi, including all 0.1 psi values therebetween).

(vii) The finishing solution then leaves the pump (7) and passes through at least one valve (SB) (e.g., a series of valves) (SB) that control flow to the at least one nozzle (9).

(viii) The at least one nozzle (9) then applies (e.g., sprays at/on) the finishing solution on a 3D-printed object in order to remove undesired support material.

(ix) Located below the 3D-printed object may be the tank (12), and the finishing solution that has been sprayed may he collected and sent to the tank (12).

(x) The finishing solution may be applied until the desired support material is removed,

(xi) The finished part is then optionally rinsed with water to remove finishing solution that may remain on the object

{0045] With regard to step (ίn), the finishing solution can enter a holding tank (12) of a machine, such as, for example, the Post Process BASE/DECi, and the tank may be filled until a level sensor Is activated. Activation of the level sensor may result In stopping additional flow of finishing solution into the tank (12).

|0046| With regard to (viii), the machine (e.g., the Post Process BASE/DECI) may ave a plurality of nozzles (9). For example, in the DEC1, there is a single set of nozzles controlled by a single valve (8B) arranged below a support tray (14) on which the 3D-printed object is placed during the application process. The support tra (14) can he perforated to allow the fini shing solution to pass from the top of the support tray to a space below the support tray ( 14). T here can also be three other sets of nozzles (9) arranged above the support tray (14) that apply the finishing solution down towards the object. Each set of nozzles (9) may be associated with its own How control valve (8Bj to permit control of the flow of finishing solution to tha nozzle set (9) In some embodiments of the invention, the nozzles (9) can be moved in the horizontal (i.e., substantially perpendicular to gravity) axis via electric motors to ensure more even application of the finishing solution to the object.

(0047] T he following examples are presented to illustrate certain aspects of the invention. They are not intended to be limiting in any way.

EXAMPLE 1

|0048j This example describes a method of use of a finishing solution that is in keeping with the invention.

(11049 J A 3D~printed object (phone case) was printed using FDM techniques (Figures

1 A and IB). The phone case comprised ABS polycarbonate and the support material comprised S 30. The following finishing solution was used to remove the support material:

(a) 4% by volume Component A;

(b) 1% by volume Component B; and

(c) the remainder was water.

Component A was:

(a) 50% by weight 45% by weight aqueous KOH;

(b) 1% by weight sodium sulfate;

(c) 0, 1% by weight sodium bicarbonate;

(d) 0.1 % by weight potassium carbonate; and

(e) the remainder was water.

Component B was:

(a) 95% by weight di(propyiene glycol) methyl ether f TTPIvP); and

(b) the remainder was Frans 280.

[00S0j The finishing solution was applied to the unfinished phone case using a "Post

Process SR BASE” machine. Briefly. Component A and Component B were arranged in separate containers (3 and 5) (see Figure 3). The inputs of the first volumetric chemical dispenser (e.g., DOSATRON ¾ ) were connected to a water line and Component A The volumetric chemical dispenser dispensed a mixture of 4% Component A (4 : 96, Component A : water) into a second volumetric chemical dispenser that was placed in series with the first volumetric chemical dispenser. The second volumetric dispenser dispensed a mixture of 1 % Component B (1 : 99, Component B : Component A/water) into a tank (12). The 3D-printed object was then placed on a perforated support tray (14) with the open tank (12) directly beneath the perforated support tray (14) and the finishing solution was applied to the object by spraying. T he 30-printed object was sprayed for approximately 60 minutes, with the pump discharge pressure at 35 psi, and a rate of 40 gallon/mhmte for the entire duration of application. The finishing solution was sprayed at a temperature of 130 °F. After the object was sprayed, the object was rinsed with water for approximately 1. minute. The object resulting from this procedure (e.g., with support material removed) is shown in Figures 1C and ID.

EXAMPLE 2

{0051] This example describes a method of use of a finishing solution that is in keeping with the invention.

{00521 A 3D~printed object was printed using PDM techniques (Figures 2A an 2B).

The object comprised ABS polycarbonate, and the support material comprised SR30. Thefinishing solution used to remove the support material was:

(a) 4% by volume Component A;

(b) 1 % by volume Component B; and

(c) the remainder was water.

Component A was:

(a) 50% by weight 45% by weight aqueous KOFI;

(b) 1% by weight sodium sulfate;

(c) 0.1% by weight sodium bicarbonate;

(d) 0.1% by weight potassium carbonate; and

(e) the remainder was water.

Component B was:

(a) 95% by weight di(propylene glycol) methyl ether 'DPM ' ’); and

(b) the remainder was 1 ' rans 280.

{0053] T he finishing solution was applied to the object using a "'Post Process SR

BAS FT machine. Briefly, Component A and Component B were arranged in separate containers (3, 5) (see Figure 3). The inputs of the first volumetric chemical dispenser (2)

(e.g., DOSATRON ® ) were connected to a water line (1) and a first tank (3) holding

Component A. The volumetric chemical dispenser (2) dispensed a mixture of 4% Component A (4 : 96, Component A : water) into a second volumetric chemical dispenser (4) that was placed m series with the first volumetric chemical dispenser (2). The second volumetric dispenser (4) dispensed a mixture of 1% Component B (1 : 99, Component B : Component A/water) into a tank (12). The 3D-printed object was then placed on a perforated support tray (14) with the open tank (12) directly beneath the perforate support tray (14) and the finishing solution was applied to the object by spraying. The 3D-prinied object was sprayed tor approximately 40 minutes, with the pump discharge pressure at of 35 psl, and a rate of 40 gaiion/minute for the entire duration of application . The finishing solution was sprayed at a temperature of 130“F. After the object was sprayed, the object was rinsed with water for approximately 1 minute. The object resulting front this procedure (e.g., with support material removed) is shown in Figures 2C and 2D.

(0054j Although the present invention has been described with respec to one or more particular examples, it will be understood that other examples of the present invention may be made without departing fro the spirit and scope of the present invention. Hence, the present invention is deemed limited onl by the appended claims and the reasonable interpretation thereof.