US 12,473,434 B2
Composition for liquid-based additive manufacturing
Dmitry Fomitchev, Lexington, MA (US); Paul S. Palumbo, West Newton, MA (US); Jodi A. Bates, Chelmsford, MA (US); Xiaofeng Zhang, Shrewsbury, MA (US); Russell H. Lewis, Westford, MA (US); Eugene N. Step, Newton, MA (US); Andriy Korchev, Westford, MA (US); Joshua M. Wimble, Chelmsford, MA (US); Patrick Sargent, Medford, MA (US); and Bjoern Schimmoeller, Oxford (GB)
Assigned to Cabot Corporation, Boston, MA (US)
Appl. No. 17/795,725
Filed by Cabot Corporation, Boston, MA (US)
PCT Filed Feb. 3, 2021, PCT No. PCT/US2021/016379
§ 371(c)(1), (2) Date Jul. 27, 2022,
PCT Pub. No. WO2021/158636, PCT Pub. Date Aug. 12, 2021.
Claims priority of provisional application 63/088,142, filed on Oct. 6, 2020.
Claims priority of provisional application 62/970,124, filed on Feb. 4, 2020.
Prior Publication US 2023/0100957 A1, Mar. 30, 2023
Int. Cl. C09C 1/30 (2006.01); B29C 64/106 (2017.01); B33Y 10/00 (2015.01); B33Y 70/10 (2020.01); C08K 3/36 (2006.01); C08K 9/06 (2006.01); C08K 9/08 (2006.01)
CPC C09C 1/3081 (2013.01) [B29C 64/106 (2017.08); C08K 3/36 (2013.01); C08K 9/06 (2013.01); C08K 9/08 (2013.01); B33Y 10/00 (2014.12); B33Y 70/10 (2020.01); C01P 2006/22 (2013.01)] 7 Claims
OG exemplary drawing
 
1. A method of forming a three-dimensional object, comprising:
a) contacting a substrate with a reservoir of prepolymer composition, the prepolymer composition comprising a resin comprising monomers and oligomers of polymers selected from acrylates, methacrylates, vinyl polymers, olefins, silicones, and epoxies and silica-containing particles selected from i) 0.1-50 wt % colloidal silica particles having a particle size of 5 nm-600 nm treated with at least one surface treatment agent, and ii) 0.1-50 wt % silica-polymer composite particles having a particle size of 10 nm-3 microns and comprising colloidal silica particles treated with at least one surface treatment agent, wherein the surface treatment agent comprises an organopolysiloxane, an organosiloxane, an organosilane, a haloorganosilane, or an organosilazane, and wherein the prepolymer composition has a viscosity no more than 500 cP greater than the neat resin at a temperature of 25° C. and a shear rate of 100 s−1;
b) selectively exposing the prepolymer composition imagewise to actinic radiation to form solid polymer at the substrate and having a build surface parallel to the substrate, the solid polymer being a sequential portion of the three-dimensional object;
c) contacting the build surface with the prepolymer composition;
d) selectively exposing the prepolymer composition to actinic radiation to increase the mass of the solid polymer, the additional polymer being a subsequent sequential portion of the three-dimensional object and
e) repeating steps c) and d) until the three dimensional object is formed.