Method for printing 3D parts and support structures with electrophotography-based additive manufacturing
A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system. The method includes developing a support layer of the support structure from a soluble support material with a first electrophotography engine, and transferring the developed support layer from the first electrophotography engine to a transfer medium. The method also includes developing a part layer of the three-dimensional part from an ABS part material with a second electrophotography engine, and transferring the developed part layer from the second electrophotography engine to the transfer medium. The method further includes moving the attracted part and support layers to a layer transfusion assembly with the transfer medium, and transfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly.
1. A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system, the method comprising:
providing a support material compositionally comprising a first charge control agent and a first copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups, and anhydride groups;
providing a part material compositionally comprising a second charge control agent, and a second copolymer having acrylonitrile units, butadiene units, and aromatic units;
developing a support layer of the support structure from the support material with a first electrophotography engine;
transferring the developed support layer from the first electrophotography engine to a transfer medium;
developing a part layer of the three-dimensional part from the part material with a second electrophotography engine;
transferring the developed part layer from the second electrophotography engine to the transfer medium
moving the attracted part and support layers to a layer transfusion assembly with the transfer medium; and
transfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly.
2. The method of claim 1 , wherein the support material has a glass transition temperature that is within about 10° C. of a glass transition temperature of the part material.
3. The method of claim 2 , wherein the glass transition temperature of the support material is within about 5° C. of the glass transition temperature of the part material.
4. The method of claim 1 , wherein the support material has a dynamic viscosity at 200° C. that is within about 10 kilopascal-seconds of a dynamic viscosity at 200° C. for the part material.
5. The method of claim 4 , wherein the dynamic viscosity of the support material is within about 5 kilopascal-seconds of the dynamic viscosity at 200° C. for the part material.
6. The method of claim 1 , wherein the first copolymer of the support material has an anhydride conversion that is at least 90% of a maximum anhydride conversion for the first copolymer.
7. The method of claim 1 , wherein the first copolymer of the support material is polymerized from monomers comprising styrene, n-butyl acrylate, and methacrylic acid.
8. The method of claim 1 , wherein the support material and the part material are each provided in a powder fog n independently having a D50 particle size ranging from about 5 micrometers to about 30 micrometers.
9. The support material of claim 8 , wherein the powder forms of the support material and the part material also independently have a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 1.40.
10. A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system, the method comprising:
providing a charged support material that compositionally comprises a first copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups, and anhydride groups;
providing a charged part material that compositionally comprises a second copolymer having acrylonitrile units, butadiene units, and aromatic units, wherein the charged support material has a dynamic viscosity at 200° C. that is within about 10 kilopascal-seconds of a dynamic viscosity at 200° C. for the charged part material;
developing a support layer of the charged support structure from the support material;
developing a part layer of the three-dimensional part from the charged part material;
independently transferring the support layer and the part layer to a transfer medium such that the support layer and the part layer define a combined layer;
moving the combined layer to a layer transfusion assembly to previously-printed layers of the three-dimensional part and the support structure; and
transfusing the combined layer to previously-printed layers.
11. The method of claim 10 , wherein the dynamic viscosity of the charged support material is within about 5 kilopascal-seconds of the dynamic viscosity at 200° C. for the charged part material.
12. The method of claim 10 , wherein the charged support material has a glass transition temperature that is within about 10° C. of a glass transition temperature of the charged part material.
13. The method of claim 10 , wherein the charged support material and the charged part material are each provided in a powder form independently having a D50 particle size ranging from about 5 micrometers to about 30 micrometers.
14. The method of claim 13 , wherein the powder foul's of the charged support material and the charged part material also independently have a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 1.40.
15. A method for printing a three-dimensional part and a support structure with an electrophotography-based additive manufacturing system, the method comprising:
providing a support material compositionally comprising a first charge control agent and a first copolymer having aromatic groups, (meth)acrylate-based ester groups, carboxylic acid groups and wherein adjacent carboxylic acid groups are converted anhydride groups such that a maximum conversion of carboxylic acid groups to anhydride ranges from about 60% to about 65%, relative to the initial number of carboxylic acid groups in the copolymer group prior to anhydride conversion;
providing a part material compositionally comprising a second charge control agent, and a second copolymer having acrylonitrile units, butadiene units, and aromatic units;
developing a support layer of the support structure from the support material with a first electrophotography engine;
transferring the developed support layer from the first electrophotography engine to a transfer medium;
developing a part layer of the three-dimensional part from the part material with a second electrophotography engine;
transferring the developed part layer from the second electrophotography engine to the transfer medium
moving the attracted part and support layers to a layer transfusion assembly with the transfer medium; and
transfusing the moved part and support layers together to previously-printed layers with the layer transfusion assembly.
16. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is greater than 90% of the maximum conversion.
17. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is greater than 95% of the maximum conversion.
18. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is greater than 95% of the maximum conversion.
19. The method of claim 15 and wherein the conversion of the carboxylic groups to anhydride groups is 100% of the maximum conversion.
20. The method of claim 15 , wherein the support material has a glass transition temperature that is within about 10° C. of a glass transition temperature of the part material.