Three-dimensional soap objects formed by additive manufacturing
View Patent ↗In one aspect, 3D printing systems for fabricating 3D soap objects are described herein. Such systems can form 3D soap objects from a particulate material and a fluid binder material based on design data, such as digital design data. In some cases, a 3D printing system comprises a build chamber comprising a build bed, a particulate material distribution device, and a fluid binder material dispenser. The particulate material distribution device can be configured to distribute successive layers of the particulate material on the build bed. The fluid binder material dispenser can be configured to selectively apply the fluid binder material to portions of the successive layers of particulate material in an amount sufficient to consolidate the portions to define cross-sectional portions of the object. In addition, the particulate material comprises a soap component in an amount of about 10 to 100% by weight.
1. A method for fabricating a three-dimensional soap object from a particulate material and a fluid binder material based on design data, method comprising:
a) distributing a layer of the particulate material of in a build chamber using particulate material distribution device; and
b) selectively applying the fluid binder material, using a fluid binder material dispenser, to a portion of the layer of particulate material in an amount sufficient to consolidate the portion to define a cross-sectional portion of the soap object, in accordance with the design data; and
c) repeating steps a) and b) until the three-dimensional soap object is completed
wherein the particulate material comprises a soap component in an amount of 40 to 100% by weight.
2. The method of claim 1 , wherein the particulate material or the fluid binder material further comprises one or more colorants and/or one or more fragrances.
3. The method of claim 1 further comprising removing excess particulate material from a surface of the printed object after a final amount of the fluid binder material has been applied to the particulate material of the object.
4. The method of claim 3 , wherein the excess particulate material is removed by a vacuum, a fan, or a source of pressurized gas.
5. The method of claim 1 , wherein the fluid binder material is applied to the particulate material when the particulate material is at a temperature below a melting point of one or more components of the binder material.
6. The method of claim 1 , wherein the soap component comprises one or more surfactants.
7. The method of claim 1 , wherein the soap component comprises one or more fatty acids or fatty acid salts.
8. The method of claim 7 , wherein the soap component comprises one or more sodium salts of a fatty acid.
9. The method of claim 7 , wherein the soap component comprises one or more potassium salts of a fatty acid.
10. The method of claim 1 , wherein the soap component comprises one or more organosulfates.
11. The method of claim 1 , wherein the soap component comprises one or more of sodium lauryl sulfate, sodium tallowate, sodium cocoate, sodium palm kernelate, sodium laurate, sodium myristate, sodium palmitate, sodium stearate, sodium oleate, sodium linoleate, and sodium linolenate.
12. The method of claim 1 , wherein the particulate material further comprises one or more additives selected from foaming agents, colorants, fragrances, preservatives, abrasion agents, antimicrobial agents, and antifungal agents.
13. The method of claim 1 , wherein the particulate material further comprises one or more of sodium carbonate, sodium bicarbonate, sodium chloride, citric acid, ethylenediaminetetraacetic acid or a salt thereof, sodium metasilicate, kaolin, clay, sand, pumice, and titanium dioxide.
14. The method of claim 1 , wherein the particulate material further comprises metal particles.
15. The method of claim 1 , wherein the binder material comprises an adhesive material in an amount of 10 to 100% by weight.
16. The method of claim 1 , wherein the binder material comprises a soap component in an amount of 10 to 100% by weight.
17. The method of claim 16 , wherein the soap component of the binder material comprises one or more fatty acids or fatty acid salts.
18. The method of claim 1 , wherein the binder material comprises one or more of cocoa butter, shea butter, coconut acid, palm kernel acid, and glycerin.
19. The method of claim 1 , wherein the binder material further comprises one or more additives selected from colorants, fragrances, preservatives, antimicrobial agents, and antifungal agents.
20. The method of claim 1 , wherein the particulate material is maintained at a temperature of 35° C. or below during fabrication of the object.