Methods and systems for processing photopolymerizable compositions
View Patent ↗The present disclosure provides methods including obtaining an insert comprising a sieve defining openings each having a diameter of 10 to 200 micrometers; placing a volume of a fluid containing a photopolymerizable composition and a contaminant in the insert; and subjecting the volume of the fluid to a centrifugal force to separate the contaminant from at least a portion of the photopolymerizable composition by retaining the contaminant in the insert and passing at least a portion the photopolymerizable composition through the sieve of the insert to provide a separated photopolymerizable composition. Systems are also provided, including an additive manufacturing apparatus, a centrifuge, and an insert configured to be inserted into the centrifuge. The methods and systems can advantageously assist in reclaiming photopolymerizable composition that has been contaminated, for reuse.
1. A method comprising:
a) obtaining an insert comprising a sieve defining a plurality of openings each having a diameter of 10 to 200 micrometers, wherein at least a portion of the insert is disposed in a container configured to fit in a centrifuge;
b) placing a volume of a fluid in the insert, wherein the fluid comprises a photopolymerizable composition and a contaminant; and
c) subjecting the volume of the fluid to a centrifugal force to separate the contaminant from at least a portion of the photopolymerizable composition by retaining the contaminant in the insert and passing at least a portion the photopolymerizable composition through the sieve of the insert and collected in the container to provide a separated photopolymerizable composition.
2. The method of claim 1 , wherein the contaminant comprises at least one of an oligomer, a polymer, a dust particle, lint, a plurality of cured voxels formed from the photopolymerizable composition, or a part formed of a polymerized product of the photopolymerizable composition.
3. The method of claim 1 , wherein the photopolymerizable composition exhibits shear thinning behavior.
4. The method of claim 1 , wherein the separated photopolymerizable composition further comprises a particulate filler and the method further comprises d) subjecting the separated photopolymerizable composition to homogenization.
5. The method of claim 4 , wherein the homogenization is performed under vacuum.
6. The method of claim 1 , wherein step c) is performed at ambient pressure.
7. The method of claim 1 , wherein the sieve is a first sieve and the insert further comprises a second sieve disposed adjacent to the first sieve, wherein the second sieve defines a plurality of openings each having a diameter that is smaller than the plurality of openings of the first sieve.
8. The method of claim 1 , further comprising e) subjecting the separated photopolymerizable composition to additional centrifugation to remove at least a portion of a dissolved gas or gas bubbles from the photopolymerizable composition.
9. The method of claim 1 , further comprising, prior to step a), f) selectively curing an initial photopolymerizable composition using actinic radiation to provide a three-dimensional object and the fluid comprising the photopolymerizable composition and the contaminant.
10. The method of claim 9 , further comprising g) moving the three-dimensional object and thereby generating a mass inertial force in a portion of the fluid that is disposed on the three-dimensional object, wherein the mass inertial force is generated using a centrifuge, a shaker, or a mixer that spins along one or more axes.
11. The method of claim 1 , further comprising i) analyzing the separated photopolymerizable composition for at least one of homogeneity or photoinitiator content.
12. The method of claim 1 , further comprising j) placing at least a portion of the separated photopolymerizable composition into an additive manufacturing apparatus; and k) selectively curing the separated photopolymerizable composition in the additive manufacturing apparatus using actinic radiation to form a three-dimensional object.
13. The method of claim 12 , further comprising, prior to step j) or step k), l) blending at least a portion of the separated photopolymerizable composition with a volume of an initial photopolymerizable composition.
14. A system comprising:
a) an additive manufacturing apparatus;
b) a centrifuge; and
c) an insert configured to be inserted in the centrifuge, the insert comprising a sieve defining a plurality of openings each having a diameter of 10 to 200 micrometers; and
d) a container, wherein at least a portion of the insert is disposed in a container configured to fit in the centrifuge.
15. The system of claim 14 , wherein the container has a volume that is greater than a volume of at least the portion of the insert that is sized to fit in the container.
16. The system of claim 14 , wherein the sieve is a first sieve and the insert further comprises a second sieve disposed adjacent to the first sieve, wherein the second sieve defines a plurality of openings each having a diameter that is smaller than the plurality of openings of the first sieve.
17. The system of any of claim 14 , wherein the centrifuge comprises a sensor that measures imbalances and terminates centrifugal force if the imbalance is above a threshold amount or measures fill level in the insert.