METHODS AND SYSTEMS FOR PRINTING 3D OBJECT BY INKJET
3D (three-dimensional) ink jet printing includes techniques for evaporating a carrier liquid during printing while at least a portion of dispersant remains in the printed layer; evaporating dispersant in a first layer prior to sintering the first layer and/or prior to printing a second layer; leveling an upper-layer of a printed object using a horizontal roller; and printing layers of an object, each layer with both object and support portions, resulting in an object with support, in particular, support for negative angles and molds.
1 - 62 . (canceled)
63 . A method for printing a three-dimensional object, the method comprising:
supplying ink to a printing head having a plurality of nozzles, wherein the ink includes at least carrier liquid, particles, and dispersant;
dispensing the ink from the plurality of nozzles to form a first layer;
heating the first layer to a temperature below the burn off temperature of the dispersant to evaporate the carrier liquid; and
repeatedly dispensing and heating additional layers above the first layer until a three-dimensional object is constructed.
64 . The method of claim 63 , wherein the ink includes metal particles.
65 . The method of claim 63 , wherein the ink includes ceramic particles.
66 . The method of claim 63 , wherein a size of the particles is between about 5 nanometer and 10 micrometer.
67 . The method of claim 63 , wherein heating a previously dispensed layer to evaporate the carrier liquid is done by at least one of: an electromagnetic source, a warm tray, and hot air.
68 . The method of claim 63 , wherein the dispersant binds the particles to each other after evaporation of the liquid carrier.
69 . The method of claim 63 , further comprising:
cooling a previously dispensed layer before dispensing ink to form a new layer on top the previously dispensed layer.
70 . The method of claim 63 further comprising:
using a leveling apparatus to peel off between about 5% and 30% of material of a previously dispensed layer.
71 . The method of claim 70 , further comprising:
applying sucking force via a pipe to prevent scattering of particle waste when the leveling apparatus peels off material of the previously dispensed layer.
72 . The method of claim 63 , further comprising:
heating a previously dispensed layer to or above the burn off temperature of the dispersant to disintegrate at least a portion of the dispersant.
73 . The method of claim 72 , wherein heating the previously dispensed layer to disintegrate at least a portion of the dispersant comprises heating via at least one of: a laser, a focused linear laser beam, a scanned focused pencil laser beam, focused light from a linear incandescent bulb, and focused light from a gas discharge lamp bulb.
74 . The method of claim 72 , wherein disintegrating at least a portion of the dispersant includes removing substantially all of the dispersant from the three-dimensional object.
75 . The method of claim 72 , wherein disintegrating the at least a portion of the dispersant comprises bringing the remaining dispersant in the three-dimensional object to a final concentration less than 0.1%.
76 . An additive manufacturing system for printing a three-dimensional object, the system comprising:
a printing head with a plurality of nozzles configured to dispense ink including at least carrier liquid, particles, and dispersant to form a first layer;
an energy source configured to supply heat to the first layer to a temperature below a burn off temperature of the dispersant to evaporate the carrier liquid; and
a processor configured to instruct the printing head and the energy source to repeatedly dispense and heat additional layers above the first layer until a three-dimensional object is constructed.
77 . The additive manufacturing system of claim 76 , wherein the processor is further configured to control the energy source in order to maintain a temperature of the three-dimensional object being printed in a pre-defined range of temperatures.
78 . The additive manufacturing system of claim 76 , further including a thermal buffer between the heated first layer and the plurality of nozzles.
79 . The additive manufacturing system of claim 76 , further including a leveling apparatus configured to peel off material from a previously dispensed layer.
80 . The additive manufacturing system of claim 76 , wherein the energy source is further configured to supply heat to a previously dispensed layer to or above the burn off temperature of the dispersant to disintegrate at least a portion of the dispersant.
81 . The additive manufacturing system of claim 76 , further including an additional energy source configured to supply heat above the burn off temperature of the dispersant to disintegrate at least a portion of the dispersant.
82 . A three-dimensional object, manufactured using an additive manufacturing process comprising:
supplying ink to a printing head having a plurality of nozzles, wherein the ink includes at least carrier liquid, particles, and dispersant;
dispensing the ink from the plurality of nozzles to form a first layer;
heating the first layer to a temperature below a burn off temperature of the dispersant to evaporate the carrier liquid; and
repeatedly dispensing and heating additional layers above the first layer until a three-dimensional object is constructed.