Sandia Corporation

Other

United States of America, As Represented by the Secretary of Agriculture

Stratasys, Inc.

Advanced Ceramics Research, Inc.

Icet, Inc.

Paul D Calvert

John Lang Lombardi

Kevin L Stuffle

Anthony C Mulligan

Peter Creegan

Sevim Z Erhan

Shantha Sarangapani

Zengshe Liu

K Ranji Vaidyanathan

Joseph Cesarano, Iii

Joseph Walish

Gabriel C Chambers

Robert A Hoffman

John A O'Kelly

Peter J Creegan

Composite formulations useful in the production of objects by the solid freeform fabrication method comprise (A) an epoxidized drying oil (primary resin); (B) a curing agent; (C) a fibrous filler; (D) a thixotropic agent and optionally (E) a secondary resin. These composites are characterized by unique physical properties including enhanced biodegradability.

Extrusion freeform fabrication of soybean oil-based composites by direct deposition

In a rapid prototyping system, a part is formed by depositing a bead of slurry that has a sufficient high concentration of particles to be pseudoplastic and almost no organic binders. After deposition the bead is heated to drive off sufficient liquid to cause the bead to become dilatant.

Method for freeforming objects with low-binder slurry

This invention encompasses porous, nanocrystalline, biomimetic calcium phosphate coatings of the order of 2-30 microns that can be grown on metal implants. The chemical surface treatments and methods for making the calcium phosphate coatings are disclosed. Post treatment with dilute hydrogels such as phema reinforce the inorganic structure and enhance the mechanical strength of the coatings. Methods are also disclosed for adsorbing or covalently attaching growth factor proteins to derivatives of the hydrogel coated calcium phosphate coatings. Such hydrogel reinforced calcium phosphate coatings show equivalent bone tissue growth as the currently used implants and are easily resorbed. This property in combination with the immobilized growth factors is expected to enhance the process of osseointegration of the disclosed coatings.

Biomimetic calcium phosphate implant coatings and methods for making the

An apparatus for thermal extrusion of a polymeric material to manufacture prototype mechanical elements from said polymeric material, said apparatus used for deposition of a liquefied ribbon of said polymeric material in patterned layers which solidify to form a three-dimensional prototype element, said apparatus comprising in combination, a mounting frame, said mounting frame including a mounting plate with a movable platen movable in the x and y directions, said frame further including an extrusion cylinder, said extrusion cylinder comprising a cylindrical housing having a uniform diameter cylindrical through passage, a head member having a uniform diameter bore connected with a reduced diameter, integral tip opening, said head member attached by a clamp to one end of the cylindrical housing to align the bore with the through passage, said-bore and through passage having an equal diameter, said head member including a circumferential heater to liquefy contents of the head member, a reciprocal piston slidably positioned in the cylindrical housing, and a piston actuator for driving the piston into the through passage to eject material through the tip opening.

Method and apparatus for in-situ formation of three-dimensional solid

Freeforming objects with low-binder slurry

The present invention generally relates compositions and methods for the preparation of three-dimensional bodies e.g., green bodies, ceramic-loaded green bodies, and polymer matrix composites by the controlled, sequential deposition of layers of material upon one another The method for preparing a green body comprises depositing a liquid composition having a viscosity of at least about 10 poise and comprising thermally-polymerizable components onto a base in a predetermined pattern to form a layer of the liquid composition on the base. Subsequently, at least one further layer of the liquid composition is deposited on a previously-formed layer in a predetermined pattern to form a multi-layered intermediate and, then, the multi-layered intermediate is heated to cause the thermally-polymerizable components to polymerize, providing the three-dimensional green body. Another method of the present invention provides a method for reinforcing a green body with fibers. More than simply reinforcing the body, however, this particular aspect of the present invention allows the alignment of reinforcing fibers in the body to be controlled. A further aspect of the present invention is the discovery of a novel composition which may be used to provide a three-dimensional polymer matrix composite using free-formation methods. This composition comprises at least one urethane acrylate oligomer, at least one vinyl monomer, and has a viscosity of at least 10 poise.

Methods for the preparation of three-dimensional bodies

The present invention generally relates compositions and methods for the preparation of three-dimensional bodies, e.g., green bodies, ceramic-loaded green bodies, and polymer matrix composites, by the controlled, sequential deposition of layers of material upon one another. The method for preparing a green body comprises depositing a liquid composition having a viscosity of at least about 10 poise and comprising thermally-polymerizable components onto a base in a predetermined pattern to form a layer of the liquid composition on the base. Subsequently, at least one further layer of the liquid composition is deposited on a previously-formed layer in a predetermined pattern to form a multi-layered intermediate and, then, the multi-layered intermediate is heated to cause the thermally-polymerizable components to polymerize, providing the three-dimensional green body. Another method of the present invention provides a method for reinforcing a green body with fibers. More than simply reinforcing the body, however, this particular aspect of the present invention allows the alignment of reinforcing fibers in the body to be controlled. A further aspect of the present invention is the discovery of a novel composition which may be used to provide a three-dimensional polymer matrix composite using free-formation methods. This composition comprises at least one urethane acrylate oligomer, at least one vinyl monomer, and has a viscosity of at least 10 poise.

Methods for the preparation of reinforced three-dimensional bodies

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Tucson, AZ, United States of America

Paul D Calvert