IP Library › Granted Patent US 12,409,602
Granted Patent B2
US 12,409,602 · App. 17/754,115 · Granted Sep 9, 2025

Modification of rheology and machine pathing for improved 3D printing of soft materials

Inventors: Adam Walter Feinberg (Pittsburgh, PA); Maria Stang (Pittsburgh, PA)
Assignee: CARNEGIE MELLON UNIVERSITY
B29C64/118B29C64/209B29C64/321B29C64/40B33Y10/00B33Y30/00B33Y70/00B29K2083/00B29K2105/0058
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Quick Facts
Patent No.
US 12,409,602
App. No.
17/754,115
Granted
Sep 9, 2025
Kind
B2
Abstract

A method and system for additive manufacturing are provided herein. The method comprises depositing a structure material, by a nozzle ( 810 ), into a support material ( 808 ) by applying to the structure material such that the structure material flows through the nozzle. The structure material comprises a polymer and a rheological modifier. Depositing of the structure material is repeated as necessary to create an object ( 814 ). The support material is at least partially removed from object. In various examples, the method comprises varying a print parameter from a first portion of the object to a second portion of the object, moving the nozzle away from a previously deposited layer of the object when repositioning for deposition of a subsequent layer of the object, or a combination thereof.

Claims (29)

1. An additive manufacturing method comprising: depositing a structure material, by a nozzle, into a support material by applying a force to the structure material such that the structure material flows through the nozzle, wherein the structure material comprises a thermoset polymer and a rheological modifier, wherein the support material is a viscoplastic material; repeating the depositing of the structure material to create an object comprising depositing a first layer of structure material and depositing a second layer of structure material in contact to the first layer such that the contact deforms the first layer of the structure material; and at least partially removing the support material from object, wherein the additive manufacturing method is freeform reversible embedding.

2. The method of claim 1 , wherein the structure physical comprises 0.1% to 50% by weight of the rheological modifier.

3. The method of claim 1 , further comprising curing the structure material after the depositing.

4. The method of claim 1 , wherein

the structure material comprises a yield stress and wherein applying the force to the structure material comprises applying a force of at least the yield stress to the structure material;

the structure material comprises a thixotropic property and wherein applying the force to the structure material comprises applying a force to cause the structure material to flow through the nozzle;

the rheological modifier increases the viscosity of the structure material and wherein applying the force to the structure material comprises applying a force to cause the structure material to flow through the nozzle; or

a combination thereof.

5. The method of claim 1 , wherein the structure material comprises a yield stress of the structure material is in a range of 1 Pa to 10 kPa and depositing comprising apply a force of at least the yield stress to the material.

6. The method of claim 5 , wherein the yield stress of the structure material is in a range of 10 Pa to 200 Pa.

7. The method of claim 1 , wherein the polymer comprises a silicone based polymer, an epoxy based polymer, a urethane based polymer, or a combination thereof.

8. The method of claim 1 , wherein the polymer comprises polydimethylsiloxane.

9. The method of claim 1 , wherein the rheological modifier comprises a thixotropic additive, a particle filler, a polymer-based additive, or a combination thereof.

10. The method of claim 1 , wherein the structure material comprises:

0.1% to 20% by weight of the rheological modifier, and

at least 70% by weight of the polymer, wherein the structure material exhibits a yield stress in a range of 1 Pa to 10 kPa and the force is at least as greater as the yield stress.

11. The method of claim 10 , wherein the yield stress of the structure material is in a range of 10 Pa to 200 Pa.

12. The method of claim 10 , wherein

the polymer comprises a silicone based polymer, an epoxy based polymer, a urethane based polymer, or a combination thereof; and

the rheological modifier comprises a thixotropic additive, a particle filler, a polymer-based additive, or a combination thereof.

13. The method of claim 10 ,

wherein the polymer comprises polydimethylsiloxane,

wherein the rheological modifier comprises a thixotropic additive.

14. The method of claim 10 , wherein the structure material comprises

1% to 10% by weight of the rheological modifier, and

at least 90% by weight of the polymer.

15. The method of claim 10 , wherein the structure material comprises an elastic modulus in a range of 0.1 MPa to 10 GPa.

16. The method of claim 10 , wherein the structure material comprises an elastic modulus in a range of 0.1 MPa to 10 MPa.

17. The method of claim 1 , wherein the structure material comprises an elastic modulus in a range of 0.1 MPa to 10 GPa.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 24, 2022
From: FEINBERG, ADAM WALTER; STANG, MARIA
To: CARNEGIE MELLON UNIVERSITY
Reel/Frame 059388/0291 →
Continuity (2)
Provisional Application 62973696 · Oct 18, 2019
Related Publication 20220332040A1 · Oct 20, 2022
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