Indian Patents. 259209:A FEEDSTOCK FOR MAKING A SUPPORT STRUCTURE FOR A THREE-DIMENSIONAL OBJECT USING AN ADDITIVE PROCESSING TECHNIQUE

Title of Invention	A FEEDSTOCK FOR MAKING A SUPPORT STRUCTURE FOR A THREE-DIMENSIONAL OBJECT USING AN ADDITIVE PROCESSING TECHNIQUE
Abstract	The present invention is a composition for making a three dimensional object. The composition comprises a plas-ticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solulion.

Full Text	WO 2006/020279 PCT/US2005/025507 SOLUBLE MATERIAL AND PROCESS FOR THREE-DIMENSIONAL MODELING BACKGROUND OF THE INVENTION This invention relates to the fabrication of three-dimensional objects using additive process modeling techniques. More particularly, the invention relates to forming three-dimensional objects by depositing solidifiable material in a predetermined pattern and providing support structures to support portions of such a three-dimensional object as it is being built Additive process modeling machines make three-dimensional models by building up. a modeling medium, based upon, design data provided from a computer aided design (CAD) system-Three-dimensional models are used for functions including aesthetic judgments, proofing the mathematical CAD model, forming hard, tooling, studying interference and space allocation, and testing': functionality. One technique is to deposit solidifiable modeling material in a predetermined pattern, according to design data provided from a CAD system, with the build-up of multiple layers forming the model. Examples of apparatus and methods for making three-dimensional models, by depositing layers of solidifiable modeling material from an extrusion head are described in Crump U.S. Patent No. 5,121,329, Batchelder, et.aL.U-S. Patent No..5,303,141, Crump. . U.S. Patent No. 5,340,433, Batchelder, .et al. U.S. Patent No. 5,402,35.1, Danforth,..et.al U.S.. Patent No.. 5,738,8.17, Batchelder, et . al. U.S. Patent No. 5,754,521 and Swanson etal. U.S..Patent-No. 6,004,124, all of which are assigned to Stratasys, Inc. of Eden Prairie, MN, the assignee of the present invention. The modeling material may be supplied to the extrusion head in solid form, for example in the form of a flexible filament wound on a supply reel or in the form of a WO 2006/020279 PCT/US2005/025507 2 solid rod, as disclosed in U.S. Patent No. 5,121,329. As described in U.S. Patent No. 4,749,347, modeling material may alternatively be pumped in liquid form from a reservoir. In any case, the extrusion head extrudes molten modeling material from a nozzle onto a base; The extruded material is. deposited layer-by-layer in areas defined from the. CAD model. A so!idifiable material which adheres to the previous layer with an adequate bond upon solidification is used as the modeling material. Thermoplastic materials have been found particularly suitable for these deposition modeling techniques. Examples of apparatus and methods far making three-dimensional models by depositing solidifiable material from a jetting head are described; for example, in Helinski U.S; Patent. No. 5,136,515, Masters U.S. Patent No. 4,665,492 and Masters U.S. Patent No. 5,216,616. Particles are directed to specific locations in a predetermined pattem-as defined by a CAD model an deposited and built up to construct the desired object In creating three-dimensional objects by-additive process techniques, such as by depositing layers of soliditiable material, it is the rule rather than the exception that supporting layers or structures must be used underneath overhanging portions or in cavities of objects under construction, which are not directly supported by the modeling material itself. For example, if the object is a model of the interior of a subterranean cave and the cave prototype is constructed from the floor towards the ceiling, then a stalactite will require a temporary support until the ceiling is completed. Support layers or structure may be required for other reasons, as well, such as allowing the model to be removed from a base, resisting a tendency for the model to deform while partially completed, and resisting forces applied to a partially completed model by the construction process. A support structure may be built utilizing the same deposition techniques and apparatus by which the modeling material WO 2006/020279 PCT/US2005/025507 3 is deposited. The apparatus, under appropriate software control, produces additional geometry acting as a support structure for the overhanging or free-space segments of the object being formed. Support material is deposited either from a separate dispensing head within the modeling apparatus, or by the same dispensing head that deposits modeling material. The support material is chosen so that it adheres to the modeling material. Anchoring the model to such support structures solves the problem of building the model, but creates the additional problem of removing the support structure from the finished model without causing damage to the model The problem of removing the support structure has been addressed by forming a weak, breakable bond between the model and the support structure, such as is described in Crump, et al. U.S. Patent No. 5,503,785. The 785 patent discloses a process by which a material that forms a weak, breakable bond with the modeling material is selected as a release material. The release material is deposited along the interface between the object and its support structure in a layered fashion or as a coating, permitting the support structure to be broken away after formation of the object The support structure may be formed of the modeling material or it may be formed of the release material. The 785 patent discloses various combinations of materials that may be used as modeling and release materials. For instance, the 785 patent discloses that at soluble release material may be utilized, so that any such material remaining on the model after the support is broken away can be removed by placing the model in a bath. Water soluble wax, polyethylene oxide and glycol-based polymers, polyvinyl pyrrolidone-based polymers, methyl vinyl ether, maleic acid-based polymers, polyoxazoline-based polymers and polyquaternium II are disclosed, as well as solvent-soluble acrylates WO 2006/020279 PCT/US2005/025507 4 and stearic and azelaic acids. Soluble supports can eliminate scarring of the model surface and the need to use force in removing supports. In extrusion based systems, a variation of applying release material in layers has been implemented, in which the release material is applied in short bead segments.. (termed "perforations") between the support structure and the model under construction. The perforations reduce adhesion of. the support layer by limiting the area of contact with the model, to aid in the removal of breakaway supports. There is a continuing need to provide a support structure that releases from a three-dimensional model without the application of force and that will not mar the model surface finish, and that further has good mechanical strength and is compatible with the modeling-process and the modeling material. BRIEF SUMMARY OFTHE INVENTION. The present invention relates to a composition for making a three-dimensional object The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, and where the composition is soluble in an alkaline solution. The present invention further relates toa composition for making a three-dimensional object where the composition comprises, a carboxylic acid-containing polymer. The composition is soluble in an alkaline solution and exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1,2 kilogram load at 230°C. . The present: invention, further relates to a method, of making a three-dimensional article. The method comprises depositing a composition onto a base, where the composition comprises a base polymer derived from a carboxylic acid, and allowing the composition to solidify. The composition is soluble in an alkaline solution and WO 2006/020279 PCT/US2005/025507. 5 exhibits a-melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a diagrammatic illustration of a model formed by a filament-feed extrusion apparatus using the alkali-soluble material of the present invention as a support structure. Fig. 2 is a perspective view (portions broken away) of the model of Fig. 1 in an alkaline bath used in practicing the process of the present invention. DETAILED DESCRIPTION The process of the present invention employing an alkali-soluble thermoplastic material is applicable for use in three-dimensional modeling systems which deposit molten modeling material that solidifies to form an object The present invention is described with reference to a deposition modeling system of the type disclosed in U.S. Patent. No., 5,121,329 and U.S. Patent No. 6,004,124, which are hereby incorporated by reference as if set forth fully herein. In the described embodiment, the modeling material and the support material are deposited as substantially continuous strands layer-by-layer from an extrusion head and are supplied, to the extrusion head in the form of a . flexible filament. It will be understood by those skilled in the art that the invention can be practiced with advantage in various other types of modeling machines as well, and that the materials may be supplied in alternative forms, such as a liquid, solid rod, pellet or granulated-form. FIG1 shows an extrusion apparatus 10' builging model 26 supported by a support" structure 28 according to the present invention. The extrusion apparatus 10 includes an extrusion head 12, a material-receiving base 14, a filament supply spool 16 and a control 18. Examples of suitable systems for the extrusion apparatus 10 include Stratasys FDM® systems, such as Stratasys FDM®. 1650,. WO 2006/020279 PCT/US2005/025507 6 Stratasys FDM® 2000, Stratasys FDM® Titan, Stratasys FDM® Vantage, and Stratasys FDM® Maxum; and "Dimension SST 3D Printer"; all available from Stratasys, Inc., Eden Prairie, MN. Extrusion head 12 moves in X and Y directions with 5 respect to base. 14, which moves in a vertical or Z direction. Supply spool 16 supplies a flexible filament 20. to extrusion head .12. Filament 20 typically follows a rather tortuous path through extrusion apparatus 10, and is advanced towards extrusion head 12 by means of stepper motor-driven pinch rollers. Filament 20 is melted in a liquifier 22, carried by extrusion head T2. The liquifier22.heats the filament to a temperature slightly above its solidification point, reducing it to a molten state: Molter material is extruded through an orifice 24 of liquifier 22 onto base 14. The extrusion apparatus 10 of the disclosed embodiment has no positive cut-off valve for stopping flow of the molten material through orifice 24 when a layer, or a pass is completed. The flow is stopped by ceasing to advance .filament 20 into, extrusion head 12. The flow rate at which the molten material is dispensed onto base 14 is determined by a combination of the orifice size and the rate at which 20 filament 20 is advanced into extrusion head 12. The movement of extrusion head 12 is controlled by control 18 so as to deposit rnaterial onto base 14 in multiple- passes and layers to build three-dimensional-mode} 26 having a shape determined by stored CAD data and further to build support structure 25 28 defined so as to physically support the model 26 as it is being- built. The model 26 and its support-structure 28 are built up on the base 14 within a build envelope having an environment controlled to promote solidification. A first layer of the deposited material adheres to the base so as to form a foundation, while subsequent layers of material 30 adhere to one other. A base that has been successfully used is a polymer foam removably mounted to a platform. Other materials that WO 2006/020279 PCT/US2005/025507 7 may serve as a base include sandpaper formed of a fine wire mesh-screen coated with sand and adhered to a platform, a water-soluble wax, a foam plastic material, and an acrylic sheet mounted to a vacuum platen. A modeling material A is dispensed to. form the tnodel 26. An alkali-soluble support material B is dispensed in coordination with the dispensing of modeling material A to form the support structure 28. For convenience, the extrusion apparatus 10 is shown with only one filament supply spool 16 providing a single filament 20. It should be-understood, however; that in the practice of the present invention using a filament-feed apparatus such as disclosed herein the modeling material A and the alkali-soluble support material-B are provided to the extrusion apparatus 10 on separate filament supply spools. The extrasfon apparatus 10 may then accommodate the dispensing of two different materials by(1) providing two exrtrusion heads 12, one supplied with modeling material A and. one- supplied; with modeling material B (such as is. disclosed in the '124 patent); (2) providing a single extrusion head supplied with both the modeling : material A and the alkali-support material B, with a single nozzle for dispensing both materials (such as shown in FIG. 6 of the '329 patent); or (3) providing a single extrusion head supplied, with both materials,: with each material dispensed through a separate-nozzle (such as shown in FIG. 6 of the '785 patent). Modeling material A is typically a thermoplastic material that can be heated relatively rapidly from a solid state to a predetermined- temperature-above the solidification-temperature of the. material, and preferably has a relatively high tensile strength. An acrylonitrile-butadiene-styrene (ABS) composition is one particularly suitable modeling material.' Other materials that may be used for the modeling material A include a variety of waxes, paraffin, a variety of WO 2006/020279 PCT/US2005/025507 8 thermoplastic resins, metals and metal alloys. Glass and chemical setting materials, including two-part epoxies, would also be suitable. Alkali-soluble support material B of the present invention is a thermoplastic soluble in an alkaline solution, as described in more detail below. Alkali-soluble support material B likewise can preferably be heated relatively rapidly from a solid state" filament to a predetermined temperature above the solidification temperature of the material, and solidify upon a drop in temperature after being dispensed. The soluble support structure 28 created with support material B may be formed in a known manner, such as disclosed in U.S. Patent No. 5,503,785r which is hereby incorporated by reference as if set forth fully herein. Figures 3-5 of the 785 patent illustrate a removable support structure. As shown in FIG. 1 herein, the support stmcture28 may be built entirely out:ofttftesupport«ratefJal B: Or, as shown and described in the 785 patent, the- alkali-soluble support material B may form a dissolvable joint between the model formed of modeling material A and a support structure formed of the same material A. The joint can be a release layer or layers, or a thin coating. After completion of the model 26, the support structure 28 is removed from the model 26 by soaking the model 26 with its attached support structure 28 in a bath 40 containing an alkaline solution C. In the embodiment shown in- FIG. 2, bath 40 is an ultrasonic, temperature-controlled bath which contains a removable mesh basket 42 for holding the model 26. The temperature of bath 40 is set using a temperature control 44. The alkaline solution C is an aqueous solution that can be washed down the drain for disposal. The temperature of the solution C in bath 40 can be heated to speed dissolution of support material B. An ultrasonic frequency generator 46 having an on/off switch starts and stops the ultrasonic transmission. WO 2006/020279 PCT/US2005/025507 9 The ultrasonic-frequency transmission generates air bubbles which assist in dissolving away the support material B by vibrating the model. Model 26 remains in bath 40 until the support material B dissolves. The basket 42 is then removed, from bath 40. The basket 42 can be placed in a sink and the Solution C rinsed, off of the model 26 with water and washed, down the drain. Bath 40 has a drain 48 from which a plug is removed to drain the solution C from the bath 40. As an alternative to removing support structure 28 from the model 26 by dissolving the alkali-soluble support material B in a bath, the support material may be dissolved using: water jets operated by hand or by automation. The base 14 may be removed from the model 26 before placing the model in the bath 40. Alternatively, the base 14 may remain adhered to model 26 as it is placed in bath 40. In the latter case, an alkali-soluble base may be desired such as an alkali-soluble foam. The alkali-soluble support material B must satisfy a large number of modeling criteria for the particular modeling system in which it is used, relating generally to thermal properties, strength, viscosity and adhesion. As to thermal properties, the alkali-soluble support material B must not deform at the-temperature in the build envelope, so as to maintain structural fidelity of the model that it supports, It is therefore desired that the alkali-soluble support material B have a glass transition temperature (Tg) at least 10°C above-the build envelope temperature. Further, if the glass transition temperature of alkali-soluble support material B. is lower than that of modeling material A, the rate of dissolution of alkali-soluble support material B may be increased by temperature control. The alkali-soluble support material B must have a melt viscosity suitable for the modeling process. In a modeling system of the type described herein, the melt viscosity must be low enough at WO 2006/020279 PCT/US2005/025507 10 the liquifier temperature so that ft can be extruded through the orifice of the liquifier as a generally continuous strand or bead and so that deposited strands or beads of alkali-soluble support material B have little melt strength, allowing them to lay flat rather than curl up. Melt viscosity is lowered by increasingtheternperaturein the liquifier.. Too. high a liquifier temperature, however, cart cause material sitting idle in the liquifier to decompose. If decomposed, in the case of an extrusion head that has no positive cut-off mechanism, support material B will drain uncontrollably from the liquifier into the build envelope, a condition: referred, to as "ooze".In practice,viscosity may be measured by its inverse parameter, melt flow. A desirable melt flow index for alkali-soluble support material. B is between about 1. g/10 minutes and about 10 grams/10 minutes, as measured pursuant to ASTM D1238, under a load of t.2 kg at 230°C, and is preferably betweeaabout5grams/1Q minutes to about 10,grams/10 minutes, To properly support the model under construction the alkaff-soluble support material B must bond to itself (self-laminate) and bond weakly to modeling material A (co-laminate). Where the support. structure is built "up from the base, alkali-soluble support material B must additionally bond to the base 14. The add .content in alkali-soluble support material B of tha present invention makes the material fairly sticky, so that it will adequately adhere to a base made of any number of materials. . For example, a polyurethane;foam base has been successfully, utilized in the practice of the invention: To produce an accurate model, alkali-soluble support material B -must also exhibit little shrinkage upon cooling in the-conditions~ of the build envelope, or, the shrink characteristics must match those of modeling material A. A shrink differential in the materials would cause stresses and bond failures along the model/support structure joint. WO 2006/020279 PCT/US2005/025507 11 Alkali-soluble support material B.must have sufficient mechanical strength in solid form to provide support to a model during its formation. The alkali-soluble support material B must resist forces by the modeling material A, or the model will exhibit undesirable curling and deformation. Additionally, alkali-soluble support material B, when supplied in filament or rod form, must be strong enough to be " shipped without breaking. When supplied in filament form, alkali-soluble support material B must further have the strength and flexibility to be formed into a filament, be spooled and unspooled, and be fed through the extrusion apparatus without breakages Similarly, alkali soluble support material B supplied in filament form must have sufficient rigidity to not be deformed by compressive forces during feeding through the extrusion apparatus. A tensile strength on the order of 1000-5000 psi is typically appropriate for deposition modeling applications Solubility characteristics, required, of alkali-soluble-support material B are that it be readily soluble in an alkaline solution (pH 7 or higher) that does not adversely affect the modeling material A. As used herein, a material is "soluble in an alkaline solution" if the material is substantially dissolvable and/or dispersibie in a solution with a pH of about 7 or higher and a temperature ranging, from about 25°C to about 80°C. It is additionally desirable that the solution be non-toxic and non-flammable, so that it requires no special handling or disposal by users. The alkali-soluble- support material B of the present invention is comprised of a base, polymer which may include a1 first comonomer; (which contains carboxylic acid) and a second comonomer that is polymerized with the first comonomer (e.g., via free-radical polymerization) to provide thermal and toughness properties suitable for deposition modeling. An alkyl methacrylate (including methyl, ethyl, propyl and butyl methacrylate), or a WO 2006/020279 PCT/US2005/0255O7 12 combination of alkyl meihacrytates, is a suitable second comonomer. Other monomers may be used as the second comonomer, that achieve the thermal and toughness characteristics desired for the modeling system in which the alkali-soluble-support material B will be used. A preferred base polymer is comprised of methacrylic acid as the first comonomer and methyl methacrylate as the second comorromer. A desirable amount of the acid-containing first comonomer is 15-60 weight percent of the base polymer. The solubility of the- alkali-soluble support material B. is due to the, carboxylic acid in the base polymer. As the acid content of the base polymer increases, the required alkalinity (pH) of the alkaline, solution used to dissolve it decreases. Optionally, additional monomers can be incorporated into the-base polymer. The alkali-soluble support material B of .the present-invention may also include a plasticizer to attain rheological properties desired for the modeling process. Selection of an appropriate plasticizer depends on a number of factors. . The plasticizer must: plasticate the dry base polymer into a processable thermoplastic meeting the desired criteria. In addition, the plasticizer must be compatible with the base polymer. Compatibility is determined by polarity, dispersion and hydrogen-bonding forces, as shown by Small's solubility parameters of 8.0 or higher, preferably 8.5 or higher (using Small's molar attraction.constant method), or as shown by Hansen's solubility parameters of 17.0, preferably 17.5 or higher (from Hansen: method described in Handbook of Solubility Parameters: CRC Press. (1991). The- plasticizer must not exhibit exudation in the formot art. oily film on the plastidzed polymer. The plasticizer must have a tow vapor pressure at material processing and modeling temperatures, preferably less than 10 mm Hg at 200°C and less than 20 mm Hg at WO 2006/020279 PCT/US2005/025507 13 250°C. The plasticizer must additionally be hydrolyzable soluble, emiulsifiable or dispersable in an alkali solvating bath, pH 7 or higher. A plasticizer reduces viscosity (i.e., increases the melt flow index) and also lowers the glass transition temperature of a polymer. As such, the concentration of plasticizer in the alkali-soluble support material B desirably provides, the desired, glass transition temperatures and melt flow indexes discussed above. For example, the thermoplastic soluble support material B desirably exhibit glass transition temperatures at least 10°C above the build envelope temperatures. Similarly, the alkali-soluble support material B.desirably exhibits a melt flow index ranging from about 1 gram/10 minutes to about 10 grams/10 minutes, (preferably between 5 grams/10 minutes and 10 grams/10 minutes). The concentration of plasticizer in the alkali-soluble support material B may depend on a variety of factors, such as the. materials used for the modeling material A, the materials used for the base polymer and trie plasticizer of the alkali-soluble support material B, the build envelope temperature, and the desired flow rates of the modeling material A and the alkali-soluble support material B. Examples of suitable concentrations of plasticizer in the alkali-soluble support material B range from about 0.01% to about 50% by weight, based on the total weight of the alkali-soluble support material B. Examples of particularly suitable concentrations of plasticizer in the alkali-soluble support material B range from about 5.0% to about 25% by weight, based on the total weight of the alkali-soluble support material. B Plasticizers found to be compatible include plastictzers in the general classes of dialkyl phthalates, cycloalkyl phthalates, benzyl and aryl phthalates, alkoxy. phthalates, alkyl/aryl phosphates, carboxylic acid esters, polyglycol esters, adipate esters, citrate esters, WO 2006/020279 PCT/US2005/025507 14 andesters of glycerin. Commercially available plasticizers with specific structure found to be compatible include: Acetates: cumyl phenyl acetate Glyceryl Triacetate, triacetin; Adipates: dibutoxy ethoxy ethyl adipate dibutoxy ethyl adipate di iso butyl adipate Citrates: tri-n-ethyl citrate;" acetyl tri-n-ethyl citrate; tri-n-propyl citrate; acetyl tri-n-propyl citrate; tri-n-butyl citrate; acetyl tri-n-butyl citrate; Phthalates: DBP, dibutyl phthalate(partial compatibility); BBPr butyt benzyl phthalate (total, compatibility); DBEP dibutoxy ethyl phthalate-(partial compatibility); 2 ethyl hexyl benzyl phthalate; tetramethyl axa onononyl benzyl phthalate; Bertzoates: dipropylene glycol dibenzoate; diethylene glycol dibenzoate; WO 2006/020279 PCT/US2005/025507 15 50/50 blend dipropylene glycol dibenzoate and diethylene glycoF dibenzoate; 1,4 cyclohexane dimethanol dibenzoate; glyceryl tribenzoate; cumyl phenyl benzoate; neopentyt glycol dibenzoate; pentaerythritol tetabenzoate; Phosphates: butyl phenyl diphenyt phosphate -TCP, tricresyl phosphate; 2 ethylhexyl diphenyl phosphate;-isodecyl diphenyl phosphate; C12, C16 alkyl diphenyl phosphate; isopropyiated triphenyl phosphate - Polyglycols: Polyethylene glycols; Polypropylene glycols. Particularly preferred plasticizers have- high thermal stability, and include.- ,p-t-butyphenyl diphenyl phosphate; butyl benzyl phthalate; 7-{2,6,6,8-tetramethyl-4-oxa-3-oxononyl) benzyl phthalate; C7/C9 alkyl benzyl phthalate; 2-ethythexyl diphenyl phosphate; and isodecyl dipbenyl- phosphate. Optionally, the- alkali-solubte support material B may contain oflier components as well; such as filler materials. For example, inert fillers may be selected from a polymer filler group consisting of calcium carbonate, magnesium carbonate, glass spheres, graphite, carbon black, carbon fiber, glass fiber, talc, WO 2006/020279 PCT/US2005/025507 16 wollastonite, mica, alumina; silica, kaolin, whiskers and silicon carbide. Inorganic fillers such as soluble salts may also be used. Techniques conventional in polymer chemistry are used to compound the component materials into alkali-soluble support material B. The formulation may be molded into rods, pellets or other shapes for use in the extrusion apparatus, or it may be used directly in' the apparatus without prior solidification. Alternatively, the mixture may be solidified and then granulated, for supply to the extrusion apparatus in granulated form. For use in the modeling process shown and described herein, a. granulated feedstock composition is processed through conventional extrusion apparatus to form continuous flexible filaments. Desirably these-filaments- are wound in-continuous lengths on a spool and dried. Alkali-soluble support material B in filament form is supplied to the extrusion apparatus 10 as, described above The filament 20 is typicaily of a very small. diameter, on the order of 0.070 inches, and may be as small as 0.001 inches in diameter. EXAMPLES • The present-invention is more particularly described in the following examples that are intended as illustrations only, since numerous modifications and-variationsaattthmsthe scope of the present, invention will be apparent to those-skilled in the art; Unless otherwise noted, all parts, percentages, and ratios reported in the. following examples are on a. weight basis,, and all reagents used in the examples were obtained, or are available from general chemical suppliers such as, the.Sigma Atdrich Chemical Company of Saint Louis MI, or may be synthesized by conventional techniques. EXAMPLE I The alkali-soluble thermoplastic material contains 74% of the base polymer and 26% of butyl phenyl diphenyl phosphate plasticizer. The base polymer consists of a higher and a lower WO 2006/020279 PCT/US2005/025507 17 molecular weight copolymer of methacrylic acid, and methyl methacrylate: The base polymer contains- roughty 50% of the higher molecular weight copolymer and 50% of the lower molecular weight copolymer, plus or minus 5% of each. Each copolymer contains a 1:2 weight percent ratio of methacrylic acid to methyl methacrylate. The higher molecular weight copolymer is. characterized by a high viscosity (low melt flow), and the low molecular weight copofymer is characterized by a low viscosity (high melt flow). Melt flow of the copolymers is measured by plasticizing each copolymer separately with 26. weight percent of the butyl phenyl dipnenyl phosphate, plasticizer. The melt flow index of the plastieized high molecular weight, copolymer is in the range- of 0.4-grams/10 minutes to 0.8 grams/10 minutes, as measured pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. The melt flow index of the plasfjcized low molecular, weight copolymer is in the range of 28 grams/10 minutes to 35 grams/10 minutes. The resulting thermoplastic composition, has a melt flow index of 5 grams/10 minutes to 6.5 grams/10 minutes and a glass transition temperature of about 90°C. The alkali-soluble thermoplastic material is processed into a 0.070 inch diameter filament and wound on a spool. The filament is fed to a Stratasys FDM® 1650 or a Stratasys FDM© 2000 benchtop. model machine. The molten alkali soluble thermoplastic material is extruded from a liquifier having a temperature of 200°C into a 70°C build envelope onto a polyurethane foam base. The extruded alkali-soluble thermoplastic material has a road width of about 0.020. inchesto about- 0.040 inches and a road height (slice. interval) of about 0.007 inchesto about 0.-020inches. A model is built from ABS thermoplastic having a glass transition temperature of 104°C, using the alkali-soluble thermoplastic material to form supports. The model with the attached supports is placed into an ultrasonic cleaning bath (having a scanning frequency of 25-27 Hertz), WO 2006/020279 PCT/US2005/025507 18 containing an alkaline aqueous solution of -approximately 98.7 weight percent water, 0.85 weight percent water softener; 0.30 weight percent pH adjuster and 0.15 weight percent surfactant, resulting in a pH of 11 to 13. The bath temperature is set to 70°C (the bath temperature must. remain lower than the glass transition temperature of modeling materiaf A), fn two hours time or less the supports are dissolved. An alternative base polymer formulation, combines the higher molecular weight 1:2 copolymer of methacrylic acid and methyl methacrylate with a lower molecular weight copolymer containing 40% methacrylic acid and .60% butyl methacrytate.- A further alternative base polymer formulation uses acrylic acid as the first comonomer. The further alternative was found, unacceptable- for use in the- Stratasys FDM® modeling machines, however, as it results in a base polymer having a tower glass transition temperature- lower than the build envelope temperature of the machines. EXAMPLE II The alkali-soluble thermoplastic material contains 79%. (+/-5%) of the base polymer and 21% (+/-5%) of butyl phenyl diphenyl phosphate plasticizer. The base polymer consists of a 1:1 weight percent ratio of methacrylic acid to methyl methacrylate, having a molecular weight of 135,000 grams/mole Prior to compounding the base polymer with, the- plasticizer, the base polymeris heated in a 220°C oven at low pressure torrid the polymer of water. Heating at low pressure for 10-15 hours was found, sufficient to dry the base polymer. The resultant dry polymer is -in the form of granules, which are fed into a compounder with the-plasticizer in a known--manner. The resulting alkali soluble thermoplastic material has a melt flow. index in the range of 5 grams/10 minutes to 6.5 grams/10 minutes, as measured pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. The glass transition onset temperature of the alkali-soluble. WO 2006/020279 PCT/US2005/025507 19 thermoplastic material is about 10.1:5°C and the glass transition peak temperature is about 111°C. As in Example I above, the alkali-soluble thermoplastic material is processed into a 0.070 inch diameter filament and wound on a spool. The filament is fed to a Stratasys FDM® 1650 or a Stratasys FDM® 2000 benchtop model machine.- Molten alkali-soluble thermoplastic material is extruded from a liquifier having a temperature of 235°C into a build envelope having a temperature of 70°C to 80°C, onto a polyurethane foam base. The extruded alkali-soluble thermoplastic material has a road width of about 0.020 inches to about 0.040 inches and a road height (slice interval) of about 0.007 inches to about 0.020inches. A model is built from ABS thermoplastic -having a. glass transition temperature of 104°C, using the alkali-soluble thermoplastic material to form supports. To dissolve the supports, the model is placed into an ultrasonic cleaning, bath set to 70°C and having a scanning frequency of 25-27 Hertz. containing an alkaline aqueous solution of approximately 98.7% water, 0.85% water softener, 0.30% pH adjuster, and 0.15% surfactant In two hours time or less the supports are dissolved. The alkali-soluble thermoplastic material according to this example exhibits thermal properties, mechanical strength, viscosity, adhesion, solubility and processing- characteristics suitable for three-dimensional modeling on the Stratasys filament-feed benchtop machines. EXAMPLE III The alkali-soluble, thermoplastic material has the same composition as. in Example II above,, but in this example the base polymer is not heated to release moisture. The alkali-soluble thermoplastic material is processed and extruded from a Stratasys FDM® machine as in Example II, and deposited to form a support structure for a model built of ABS thermoplastic. In this example, the alkali-soluble thermoplastic material exhibited a greater amount of WO 2006/020279 PCT/US2005/025507 20 "ooze" from the extrusion heat than is desirable, but otherwise exhibited characteristics suitable for three-dimensionai modeling. The "ooze" is attributable to water present in the composition. If used in a modeling system wherein the material dispenser has a positive cut-off mechanism, the "ooze" effect exhibited- in the- Stratasys FDW® machine would not occur and the material according to this' Example III could be effectively utilized. EXAMPLE IV Samples of alkali-soluble thermoplastic materials of the present invention were created with varying concentrations of. plasticizer to compare the effects of the plasticizer on the glass transition temperatures and the melt flow indexes. The base polymers and the plasticizers used were the same as described in Example I Table 1 provides the weight percent concentratfons of the alkali-soluble thermoplastic materials of Examples, IV(A) - Examples IV(M). As shown, the concentration of plasticizer was varied between the samples. Table 1 also provide the corresponding glass transition temperatures (Tg) and the melt flow indexes (MR) of the alkali-soluble thermoplastic materials of Examples IV(A) — Examples IV(M). The melt flow indexes were tested pursuant to ASTM D1238 under a 1.2 kilogram load at 160°C, 230°C, or.270°C. WO 2006/020279 PCT/US2005/025507- 21 TABLE 1 Composition Weight Percent Base Polymer () Weight Percent Plasticizer () Tg (°C) MFI (160°C) MFI (230°C) MR (270°C) Example IV{A) 100 0 160 Example IV(B) 98 2 156 1.1 Example IV(C) 97 3 t54 1.2 Example IV(D) 95 4 147 1.6 Example IV(E) 95 5 145 2.5 Example IV(F) 93 7 142 3.4 Example IV(G) 90 - 10 134 6.0 Example IV(H) 83 17 116 1.7 Example IV(I) 81 19 111 2.3 Example IV(J). ¦79 21 . 109 3.0 Example IV(K) 75 25 100 6.2 Example IV(L) 65 35 74 35.0 Example IV(M) 55 45 49 5.1 (*) Based of the total weight of the alkali-soluble thermoplastic material. The data in Table 1 illustrates the effects of the plasticizer concentration err the glass transition" temperature and the melt flow.index of the alkali-soluble thermoplastic materials.. In general, as the concentrations of plasticizer in the alkali-soluble thermoplastic materials increase, the gfass transition temperatures decrease and the melt flow indexes increase. As such, varying the plasticizer concentration provides a trade-off between the glass transition temperature and the melt flow index.. For the base polymer and plasticizer used-for Examples IV(A) - Examples IV(M), the glass transition temperatures ranged from about 49°C (45% plasticizer) to about 160°C (no plasticizer}, and were generally inversely linear to the concen tration of plasticizer. As discussed above, the alkali-soluble support materials of the present invention desirably exhibit glass transition temperatures at feast 10°C above the build envelope temperatures. As such, when using high build envelope temperatures (e.g., 100°C or higher), alkali-soluble thermoplastic materials with low concentrations of plasticizer are WO 2006/020279 PCT/US2005/025507 22 preferred (e.g., 25% or less) to allow the alkali-soluble thermoplastic materials to exhibit higher glass transition temperatares. With respect to the melt flow, index tested at 230°C, the data in Table 1 shows that the melt flow index increases generally in an exponential manner relative to the concentration of plasticizer. An increase from 25% to 35% plasticizer caused the melt flow index far increase from about 6 grams/10 minutes to about 35 grams/10 minutes. As discussed above, a melt flow index ranging from about 1 gram/10 minutes to about 10 grams/10 minutes is preferred. As such, a melt flow index of about 6 grams/10. minutes is considered . acceptable conditions for extruding the material. However, a melt flow index of about 35 grams/10 minutes may cause the desired physical properties to potentially deteriorate. As shown in Table 1, plasticizer concentrations of about 25% or less (Examples. IV(A) — Examples IV(K)) provide glass. transition temperatures of about 100C or greater; and melt flow . indexes of about 6 grams/10 minutes or less at 230°C. Such plasticizer concentrations provide acceptable physical characteristics "... forthe alkali-soluble thermoplastic materials of the present invention. Although the present invention has been described with reference to preferred embodiments,, workers skilled in- the art will recognize that changes may be. made in form-and detail without departing from the spirit and scope of the invention. For. example, it will be appreciated that innumerable modifications may be made to the modeling process. It will .further be appreciated that various modifications may. be made to the. composition .Also, the thermoplastic material, of the present invention could be used to an alkali-soluble three-dimensionar object having usefulness in various molding processes. For example, the alkali-soluble material can form a dissolvable master core in a cast or injection process. The alkali-soluble material can likewise be used to create a mold (by deposition WO 2006/020279 PCT/US2005/025507 23 modeling or otherwise), which mold can later be dissolved out of an object formed by molding processes. WO 2006/020279 PCT/US2005/025507 24 CLAIMS: 1. A composition for making a three-dimensional object, the composition comprising a plasticizer and a base polymer, the base polymer comprising a carboxylic acid, wherein the composition is soluble in an alkaline solution. 2. The composition of claim 1, wherein the plasticizer constitutes from about 0.01% to about 50.0% by weight of the composition, based on a total weight of the-composition. 3. The composition of claim 2, wherein the plasticizer constitutes from about 5.0% to about- 25.0% by weight of the composition, based on the a total weight of the composition. 4. The composition of claim 1, wherein the plasticizer is selected from a group consisting of p-t-butylphenyl diphenyl phosphate; butyl benzyl phthalate; 7-(2,6,6,S-tetramethyI-4-oxa-3- oxononyl) benzyl phthalate; C7/C9-alkyl benzyl phthalate; 2-ethythexyl diphenyl phosphate; isodecyl diphenyl phosphate,, and combinations thereof. 5. The composition of claim1, wherein the carboxylic acid - comprises methacrylic acid. 6. The composition of claim 5, wherein the carboxylic acid constitutes from about 15.0% to about 60.0% by weight of the base polymer, based on a total weight of the base polymer. 7. The composition of claim 1, wherein the base polymer further comprises an alkyl methacrylate. 8. The composition of claim 7, wherein the alkyl methacrylate comprises a methyl methacrylate: 9. The cornposition of claim 1, wherein the composition exhibits a glass transition temperature ranging from of about 49°C to about160°C. 10. The composition of claim 1, wherein the composition exhibits a melt flow index ranging from of about 1 gram/10 minutes to WO 2006/020279 PCT/DS2005/025507 25 about .10 grams/10 minutes when tested pursuant to ASTM D1238 under a 1.2 kilogram load at230°C. 11. The composition of claim 10, wherein the composition exhibits a melt flow index ranging from of about 5 grams/10 minutes to about 10 grams/10 minutes when tested pursuant fa ASTM D1238 under a 1.2 kilogram load at 230°C. 12. A composition for making a three dimensional object, the composition comprising a carboxylic acid-containing polymer, wherein the composition is soluble in an alkaline solution, and wherein the composition exhibits a melt flow index of about 10. grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. 13. The composition of claim 12 further comprising a plasticizer. 14. The composition of claim 13 wherein the plasticizer constitutes about 25.0% by weight of the composition or less,based on a total weight of the composition. 15. The composition of claim 12, wherein the composition exhibits a glass transition temperature of about 100°C or greater. 16. The composition of claim 12, wherein the composition exhibits a melt flow index ranging from of about 5 grams/10 minutes to about 10. grams/10 minutes when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. 17. The composition of claim. 12, wherein the carboxylic acid comprises methacrylic acid. 18. The composition of claim 42, wherein the base polymer further comprises an alkyl metnacrylate; 19. The composition of claim 18, wherein the alkyl methacrylate comprises a methyl methacrylate. 20. The composition of claim 18, wherein the carboxylic acid constitutes from about 15.0% to about 60.0% by weight of the WO 2006/020279 PCT/US2005/025507 26 carboxylic acid and the alkyyl methacrylate, based on a total weight of the carboxylic acid and the alky! methacrylate. 21. The composition of claim 18, wherein the carboxylic acid and the alkyl methacrylate are polymerized- 22. A method of malting a three-dimensional article, the. method comprising: depositing a composition comprising, a. base polymer-derived from a carboxylic acid, wherein the composition is soluble in an alkaline solution, and wherein the composition exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM. D1238 under a T.2 kilogram load at 230°C; and allowing the" composition to solidify. 23. The method of claim 22, wherein the composition is deposited and solidified in a plurality of steps so as to make a plurality of layers, wherein the layers define the three-dimensional article. 24. The method of claim '22, wherein the composition further comprises a plasticizer. 25. The method of claim 24, wherein the plasticizer constitutes about 25.0%. by weight of the composition or less, based on a total weight of the composition. 26. The method of claim 24, wherein the composition is deposited in a build envelope that exhibits a build envelope., temperature and wherein the plasticizer is concentrated- in the composition at effective levels to allow the composition to exhibit a glass transition temperature greater than the build envelope temperature. 27. The method of claim 24, wherein the plasticizer constitutes about 25.0% by weight of the composition or less, based on a total weight of the composition. • WO 2006/020279 PCT/US2005/02550r 27 28. The method of claim 27, wherein the composition exhibits a glass transition temperature of about 100°C or greater. 29. The method of claim 27, wherein the composition exhibits a melt flow index ranging from of about 5 grams/10 minutes to about 10 grams/10 minutes when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. 30. The composition of claim 22, wherein the carboxylic acid comprises methacrylic acid. 31. The composition of claim 22, 'wherein the base polymer is further derived from an alkyl methacrylate. 32. The composition of claim 31, wherein the. alkyl methacrylate comprises a methyl methacrylate. 33. In a process for making a three-dimensional object.by dispensing solidifiable modeling material in a predetermined pattern so as to define the three-dimensional object in coordination with dispensing solidifiable support material so as to define a support structure for the three-dimensional object, the support structure thereby having portions thereof in contact with the object, the improvement comprising: forming at least, those portions of the support structure contacting the object from a thermoplastic material comprising a carboxylic acid-containing polymer, wherein the composition is soluble in an alkaline solution, and wherein the composition exhibits: a melt flow index of about 10. grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. 34. The process of claim 33, wherein the thermoplastic material further comprises a plasticizer constituting from about 0.01% WO 2006/020279 PCT/US2005/025507 28 to about 50.0% by weight of the thermoplastic material, based on a total weight of the thermoplastic material. 35. An additive process for making three-dimensional objects, comprising: 5 dispensing an alkali-insoluble modeling material in a predetermined pattern defining a three dimensional-object having overhanging portions that require support during formation; and dispensing a support material in the space beneath the 10 overhanging- portions of the three-dimensional object in coordination with the dispensing of the modeling material to form a three-dimtensional support structure for the object, the support material comprising a carboxylic acid-containing 15 polymer wherein the composition is soluble in an alkaline-solution, and wherein the composition' exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C; 20 whereby the support material may be dissolved from the three-dimensional object by application of an alkaline solution. 36. The process of claim 35; wherein the support material further comprises a plasticizer; 37. The process of claim 35, wherein the support material exhibits a glass transition temperature of about 100°C or greater; 38. In a process for making three-dimensional objects by depositing solidifiable material onto a base, the improvement comprising: 30 providing as the solidifiable material a carboxylic acid- containing polymer, wherein the composition is WO 2006/020279 PCT/US2005/025507 29 soluble in an alkaline solution, and wherein the . composition exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at230°C. The present invention is a composition for making a three dimensional object. The composition comprises a plas-ticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solulion.

Full Text

WO 2006/020279 PCT/US2005/025507
SOLUBLE MATERIAL AND PROCESS FOR THREE-DIMENSIONAL MODELING
BACKGROUND OF THE INVENTION This invention relates to the fabrication of three-dimensional objects using additive process modeling techniques. More particularly, the invention relates to forming three-dimensional objects by depositing solidifiable material in a predetermined pattern and providing support structures to support portions of such a three-dimensional object as it is being built
Additive process modeling machines make three-dimensional models by building up. a modeling medium, based upon, design data provided from a computer aided design (CAD) system-Three-dimensional models are used for functions including aesthetic
judgments, proofing the mathematical CAD model, forming hard, tooling, studying interference and space allocation, and testing': functionality. One technique is to deposit solidifiable modeling material in a predetermined pattern, according to design data provided from a CAD system, with the build-up of multiple layers forming the model.
Examples of apparatus and methods for making three-dimensional models, by depositing layers of solidifiable modeling material from an extrusion head are described in Crump U.S. Patent No. 5,121,329, Batchelder, et.aL.U-S. Patent No..5,303,141, Crump.
. U.S. Patent No. 5,340,433, Batchelder, .et al. U.S. Patent No. 5,402,35.1, Danforth,..et.al U.S.. Patent No.. 5,738,8.17, Batchelder, et . al. U.S. Patent No. 5,754,521 and Swanson etal. U.S..Patent-No. 6,004,124, all of which are assigned to Stratasys, Inc. of Eden Prairie, MN, the assignee of the present invention. The modeling material may be supplied to the extrusion head in solid form, for example in the form of a flexible filament wound on a supply reel or in the form of a

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solid rod, as disclosed in U.S. Patent No. 5,121,329. As described in U.S. Patent No. 4,749,347, modeling material may alternatively be pumped in liquid form from a reservoir. In any case, the extrusion head extrudes molten modeling material from a nozzle onto a base; The extruded material is. deposited layer-by-layer in areas defined from the. CAD model. A so!idifiable material which adheres to the previous layer with an adequate bond upon solidification is used as the modeling material. Thermoplastic materials have been found particularly suitable for these deposition modeling techniques.
Examples of apparatus and methods far making three-dimensional models by depositing solidifiable material from a jetting head are described; for example, in Helinski U.S; Patent. No. 5,136,515, Masters U.S. Patent No. 4,665,492 and Masters U.S. Patent No. 5,216,616. Particles are directed to specific locations in a predetermined pattem-as defined by a CAD model an deposited and built up to construct the desired object
In creating three-dimensional objects by-additive process techniques, such as by depositing layers of soliditiable material, it is the rule rather than the exception that supporting layers or structures must be used underneath overhanging portions or in cavities of objects under construction, which are not directly supported by the modeling material itself. For example, if the object is a model of the interior of a subterranean cave and the cave prototype is constructed from the floor towards the ceiling, then a stalactite will require a temporary support until the ceiling is completed. Support layers or structure may be required for other reasons, as well, such as allowing the model to be removed from a base, resisting a tendency for the model to deform while partially completed, and resisting forces applied to a partially completed model by the construction process.
A support structure may be built utilizing the same deposition techniques and apparatus by which the modeling material

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is deposited. The apparatus, under appropriate software control, produces additional geometry acting as a support structure for the overhanging or free-space segments of the object being formed. Support material is deposited either from a separate dispensing head within the modeling apparatus, or by the same dispensing head that deposits modeling material. The support material is chosen so that it adheres to the modeling material. Anchoring the model to such support structures solves the problem of building the model, but creates the additional problem of removing the support structure from the finished model without causing damage to the model
The problem of removing the support structure has been addressed by forming a weak, breakable bond between the model and the support structure, such as is described in Crump, et al. U.S. Patent No. 5,503,785. The 785 patent discloses a process by which a material that forms a weak, breakable bond with the modeling material is selected as a release material. The release material is deposited along the interface between the object and its support structure in a layered fashion or as a coating, permitting the support structure to be broken away after formation of the object The support structure may be formed of the modeling material or it may be formed of the release material.
The 785 patent discloses various combinations of materials that may be used as modeling and release materials. For instance, the 785 patent discloses that at soluble release material may be utilized, so that any such material remaining on the model after the support is broken away can be removed by placing the model in a bath. Water soluble wax, polyethylene oxide and glycol-based polymers, polyvinyl pyrrolidone-based polymers, methyl vinyl ether, maleic acid-based polymers, polyoxazoline-based polymers and polyquaternium II are disclosed, as well as solvent-soluble acrylates

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and stearic and azelaic acids. Soluble supports can eliminate scarring of the model surface and the need to use force in removing supports.
In extrusion based systems, a variation of applying release material in layers has been implemented, in which the release material is applied in short bead segments.. (termed "perforations") between the support structure and the model under construction. The perforations reduce adhesion of. the support layer by limiting the area of contact with the model, to aid in the removal of breakaway supports.
There is a continuing need to provide a support structure that releases from a three-dimensional model without the application of force and that will not mar the model surface finish, and that further has good mechanical strength and is compatible with the modeling-process and the modeling material.
BRIEF SUMMARY OFTHE INVENTION.
The present invention relates to a composition for making a three-dimensional object The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, and where the composition is soluble in an alkaline solution.
The present invention further relates toa composition for making a three-dimensional object where the composition comprises, a carboxylic acid-containing polymer. The composition is soluble in an alkaline solution and exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1,2 kilogram load at 230°C. .
The present: invention, further relates to a method, of making a three-dimensional article. The method comprises depositing a composition onto a base, where the composition comprises a base polymer derived from a carboxylic acid, and allowing the composition to solidify. The composition is soluble in an alkaline solution and

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exhibits a-melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a diagrammatic illustration of a model formed by a filament-feed extrusion apparatus using the alkali-soluble material of the present invention as a support structure.
Fig. 2 is a perspective view (portions broken away) of the model of Fig. 1 in an alkaline bath used in practicing the process of the present invention.
DETAILED DESCRIPTION
The process of the present invention employing an alkali-soluble thermoplastic material is applicable for use in three-dimensional modeling systems which deposit molten modeling material that solidifies to form an object
The present invention is described with reference to a deposition modeling system of the type disclosed in U.S. Patent. No., 5,121,329 and U.S. Patent No. 6,004,124, which are hereby incorporated by reference as if set forth fully herein. In the described embodiment, the modeling material and the support material are deposited as substantially continuous strands layer-by-layer from an extrusion head and are supplied, to the extrusion head in the form of a . flexible filament. It will be understood by those skilled in the art that the invention can be practiced with advantage in various other types of modeling machines as well, and that the materials may be supplied in alternative forms, such as a liquid, solid rod, pellet or granulated-form.
FIG1 shows an extrusion apparatus 10' builging model 26 supported by a support" structure 28 according to the present invention. The extrusion apparatus 10 includes an extrusion head 12, a material-receiving base 14, a filament supply spool 16 and a control 18. Examples of suitable systems for the extrusion apparatus 10 include Stratasys FDM® systems, such as Stratasys FDM®. 1650,.

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Stratasys FDM® 2000, Stratasys FDM® Titan, Stratasys FDM® Vantage, and Stratasys FDM® Maxum; and "Dimension SST 3D Printer"; all available from Stratasys, Inc., Eden Prairie, MN.
Extrusion head 12 moves in X and Y directions with 5 respect to base. 14, which moves in a vertical or Z direction. Supply spool 16 supplies a flexible filament 20. to extrusion head .12. Filament 20 typically follows a rather tortuous path through extrusion apparatus 10, and is advanced towards extrusion head 12 by means of stepper motor-driven pinch rollers. Filament 20 is melted in a liquifier 22,
carried by extrusion head T2. The liquifier22.heats the filament to a temperature slightly above its solidification point, reducing it to a molten state: Molter material is extruded through an orifice 24 of liquifier 22 onto base 14.
The extrusion apparatus 10 of the disclosed embodiment
has no positive cut-off valve for stopping flow of the molten material
through orifice 24 when a layer, or a pass is completed. The flow is stopped by ceasing to advance .filament 20 into, extrusion head 12. The flow rate at which the molten material is dispensed onto base 14 is determined by a combination of the orifice size and the rate at which
20 filament 20 is advanced into extrusion head 12.
The movement of extrusion head 12 is controlled by control 18 so as to deposit rnaterial onto base 14 in multiple- passes and layers to build three-dimensional-mode} 26 having a shape determined by stored CAD data and further to build support structure
25 28 defined so as to physically support the model 26 as it is being- built. The model 26 and its support-structure 28 are built up on the base 14 within a build envelope having an environment controlled to promote solidification. A first layer of the deposited material adheres to the base so as to form a foundation, while subsequent layers of material
30 adhere to one other. A base that has been successfully used is a polymer foam removably mounted to a platform. Other materials that

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may serve as a base include sandpaper formed of a fine wire mesh-screen coated with sand and adhered to a platform, a water-soluble wax, a foam plastic material, and an acrylic sheet mounted to a vacuum platen.
A modeling material A is dispensed to. form the tnodel 26. An alkali-soluble support material B is dispensed in coordination with the dispensing of modeling material A to form the support structure 28. For convenience, the extrusion apparatus 10 is shown with only one filament supply spool 16 providing a single filament 20. It should be-understood, however; that in the practice of the present invention using a filament-feed apparatus such as disclosed herein the modeling material A and the alkali-soluble support material-B are provided to the extrusion apparatus 10 on separate filament supply spools. The extrasfon apparatus 10 may then accommodate the dispensing of two different materials by(1) providing two exrtrusion heads 12, one supplied with modeling material A and. one- supplied; with modeling material B (such as is. disclosed in the '124 patent); (2) providing a single extrusion head supplied with both the modeling : material A and the alkali-support material B, with a single nozzle for dispensing both materials (such as shown in FIG. 6 of the '329 patent); or (3) providing a single extrusion head supplied, with both materials,: with each material dispensed through a separate-nozzle (such as shown in FIG. 6 of the '785 patent).
Modeling material A is typically a thermoplastic material that can be heated relatively rapidly from a solid state to a predetermined- temperature-above the solidification-temperature of the. material, and preferably has a relatively high tensile strength. An acrylonitrile-butadiene-styrene (ABS) composition is one particularly suitable modeling material.' Other materials that may be used for the modeling material A include a variety of waxes, paraffin, a variety of

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thermoplastic resins, metals and metal alloys. Glass and chemical setting materials, including two-part epoxies, would also be suitable.
Alkali-soluble support material B of the present invention is a thermoplastic soluble in an alkaline solution, as described in more detail below. Alkali-soluble support material B likewise can preferably be heated relatively rapidly from a solid state" filament to a predetermined temperature above the solidification temperature of the material, and solidify upon a drop in temperature after being dispensed.
The soluble support structure 28 created with support material B may be formed in a known manner, such as disclosed in U.S. Patent No. 5,503,785r which is hereby incorporated by reference as if set forth fully herein. Figures 3-5 of the 785 patent illustrate a removable support structure. As shown in FIG. 1 herein, the support stmcture28 may be built entirely out:ofttftesupport«ratefJal B: Or, as shown and described in the 785 patent, the- alkali-soluble support material B may form a dissolvable joint between the model formed of modeling material A and a support structure formed of the same material A. The joint can be a release layer or layers, or a thin coating.
After completion of the model 26, the support structure 28 is removed from the model 26 by soaking the model 26 with its attached support structure 28 in a bath 40 containing an alkaline solution C. In the embodiment shown in- FIG. 2, bath 40 is an ultrasonic, temperature-controlled bath which contains a removable mesh basket 42 for holding the model 26. The temperature of bath 40 is set using a temperature control 44. The alkaline solution C is an aqueous solution that can be washed down the drain for disposal. The temperature of the solution C in bath 40 can be heated to speed dissolution of support material B. An ultrasonic frequency generator 46 having an on/off switch starts and stops the ultrasonic transmission.

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The ultrasonic-frequency transmission generates air bubbles which assist in dissolving away the support material B by vibrating the model.
Model 26 remains in bath 40 until the support material B dissolves. The basket 42 is then removed, from bath 40. The basket 42 can be placed in a sink and the Solution C rinsed, off of the model 26 with water and washed, down the drain. Bath 40 has a drain 48 from which a plug is removed to drain the solution C from the bath 40.
As an alternative to removing support structure 28 from the model 26 by dissolving the alkali-soluble support material B in a bath, the support material may be dissolved using: water jets operated by hand or by automation.
The base 14 may be removed from the model 26 before placing the model in the bath 40. Alternatively, the base 14 may remain adhered to model 26 as it is placed in bath 40. In the latter case, an alkali-soluble base may be desired such as an alkali-soluble foam.
The alkali-soluble support material B must satisfy a large number of modeling criteria for the particular modeling system in which it is used, relating generally to thermal properties, strength, viscosity and adhesion. As to thermal properties, the alkali-soluble support material B must not deform at the-temperature in the build envelope, so as to maintain structural fidelity of the model that it supports, It is therefore desired that the alkali-soluble support material B have a glass transition temperature (Tg) at least 10°C above-the build envelope temperature. Further, if the glass transition temperature of alkali-soluble support material B. is lower than that of modeling material A, the rate of dissolution of alkali-soluble support material B may be increased by temperature control.
The alkali-soluble support material B must have a melt viscosity suitable for the modeling process. In a modeling system of the type described herein, the melt viscosity must be low enough at

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the liquifier temperature so that ft can be extruded through the orifice of the liquifier as a generally continuous strand or bead and so that deposited strands or beads of alkali-soluble support material B have little melt strength, allowing them to lay flat rather than curl up. Melt viscosity is lowered by increasingtheternperaturein the liquifier.. Too. high a liquifier temperature, however, cart cause material sitting idle in the liquifier to decompose. If decomposed, in the case of an extrusion head that has no positive cut-off mechanism, support material B will drain uncontrollably from the liquifier into the build envelope, a condition: referred, to as "ooze".In practice,viscosity may be measured by its inverse parameter, melt flow. A desirable melt flow index for alkali-soluble support material. B is between about 1. g/10 minutes and about 10 grams/10 minutes, as measured pursuant to ASTM D1238, under a load of t.2 kg at 230°C, and is preferably betweeaabout5grams/1Q minutes to about 10,grams/10 minutes,
To properly support the model under construction the alkaff-soluble support material B must bond to itself (self-laminate) and bond weakly to modeling material A (co-laminate). Where the support. structure is built "up from the base, alkali-soluble support material B must additionally bond to the base 14. The add .content in alkali-soluble support material B of tha present invention makes the material fairly sticky, so that it will adequately adhere to a base made of any number of materials. . For example, a polyurethane;foam base has been successfully, utilized in the practice of the invention:
To produce an accurate model, alkali-soluble support material B -must also exhibit little shrinkage upon cooling in the-conditions~ of the build envelope, or, the shrink characteristics must match those of modeling material A. A shrink differential in the materials would cause stresses and bond failures along the model/support structure joint.

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Alkali-soluble support material B.must have sufficient mechanical strength in solid form to provide support to a model during its formation. The alkali-soluble support material B must resist forces by the modeling material A, or the model will exhibit undesirable curling and deformation. Additionally, alkali-soluble support material B, when supplied in filament or rod form, must be strong enough to be " shipped without breaking. When supplied in filament form, alkali-soluble support material B must further have the strength and flexibility to be formed into a filament, be spooled and unspooled, and be fed through the extrusion apparatus without breakages Similarly, alkali soluble support material B supplied in filament form must have sufficient rigidity to not be deformed by compressive forces during feeding through the extrusion apparatus. A tensile strength on the order of 1000-5000 psi is typically appropriate for deposition modeling applications
Solubility characteristics, required, of alkali-soluble-support material B are that it be readily soluble in an alkaline solution (pH 7 or higher) that does not adversely affect the modeling material A. As used herein, a material is "soluble in an alkaline solution" if the material is substantially dissolvable and/or dispersibie in a solution with a pH of about 7 or higher and a temperature ranging, from about 25°C to about 80°C. It is additionally desirable that the solution be non-toxic and non-flammable, so that it requires no special handling or disposal by users.
The alkali-soluble- support material B of the present invention is comprised of a base, polymer which may include a1 first comonomer; (which contains carboxylic acid) and a second comonomer that is polymerized with the first comonomer (e.g., via free-radical polymerization) to provide thermal and toughness properties suitable for deposition modeling. An alkyl methacrylate (including methyl, ethyl, propyl and butyl methacrylate), or a

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combination of alkyl meihacrytates, is a suitable second comonomer. Other monomers may be used as the second comonomer, that achieve the thermal and toughness characteristics desired for the modeling system in which the alkali-soluble-support material B will be used. A preferred base polymer is comprised of methacrylic acid as the first comonomer and methyl methacrylate as the second comorromer.
A desirable amount of the acid-containing first comonomer is 15-60 weight percent of the base polymer. The solubility of the- alkali-soluble support material B. is due to the, carboxylic acid in the base polymer. As the acid content of the base polymer increases, the required alkalinity (pH) of the alkaline, solution used to dissolve it decreases. Optionally, additional monomers can be incorporated into the-base polymer.
The alkali-soluble support material B of .the present-invention may also include a plasticizer to attain rheological properties desired for the modeling process. Selection of an appropriate plasticizer depends on a number of factors. . The plasticizer must: plasticate the dry base polymer into a processable thermoplastic meeting the desired criteria. In addition, the plasticizer must be compatible with the base polymer. Compatibility is determined by polarity, dispersion and hydrogen-bonding forces, as shown by Small's solubility parameters of 8.0 or higher, preferably 8.5 or higher (using Small's molar attraction.constant method), or as shown by Hansen's solubility parameters of 17.0, preferably 17.5 or higher (from Hansen: method described in Handbook of Solubility Parameters: CRC Press. (1991). The- plasticizer must not exhibit exudation in the formot art. oily film on the plastidzed polymer. The plasticizer must have a tow vapor pressure at material processing and modeling temperatures, preferably less than 10 mm Hg at 200°C and less than 20 mm Hg at

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250°C. The plasticizer must additionally be hydrolyzable soluble, emiulsifiable or dispersable in an alkali solvating bath, pH 7 or higher.
A plasticizer reduces viscosity (i.e., increases the melt flow index) and also lowers the glass transition temperature of a polymer. As such, the concentration of plasticizer in the alkali-soluble support material B desirably provides, the desired, glass transition temperatures and melt flow indexes discussed above. For example, the thermoplastic soluble support material B desirably exhibit glass transition temperatures at least 10°C above the build envelope temperatures. Similarly, the alkali-soluble support material B.desirably exhibits a melt flow index ranging from about 1 gram/10 minutes to about 10 grams/10 minutes, (preferably between 5 grams/10 minutes and 10 grams/10 minutes).
The concentration of plasticizer in the alkali-soluble support material B may depend on a variety of factors, such as the. materials used for the modeling material A, the materials used for the base polymer and trie plasticizer of the alkali-soluble support material B, the build envelope temperature, and the desired flow rates of the modeling material A and the alkali-soluble support material B. Examples of suitable concentrations of plasticizer in the alkali-soluble support material B range from about 0.01% to about 50% by weight, based on the total weight of the alkali-soluble support material B. Examples of particularly suitable concentrations of plasticizer in the alkali-soluble support material B range from about 5.0% to about 25% by weight, based on the total weight of the alkali-soluble support material. B
Plasticizers found to be compatible include plastictzers in the general classes of dialkyl phthalates, cycloalkyl phthalates, benzyl and aryl phthalates, alkoxy. phthalates, alkyl/aryl phosphates, carboxylic acid esters, polyglycol esters, adipate esters, citrate esters,

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andesters of glycerin. Commercially available plasticizers with specific structure found to be compatible include:
Acetates:
cumyl phenyl acetate
Glyceryl Triacetate, triacetin;
Adipates:
dibutoxy ethoxy ethyl adipate dibutoxy ethyl adipate di iso butyl adipate
Citrates:
tri-n-ethyl citrate;" acetyl tri-n-ethyl citrate; tri-n-propyl citrate; acetyl tri-n-propyl citrate; tri-n-butyl citrate; acetyl tri-n-butyl citrate;
Phthalates:
DBP, dibutyl phthalate(partial compatibility); BBPr butyt benzyl phthalate (total, compatibility); DBEP dibutoxy ethyl phthalate-(partial compatibility); 2 ethyl hexyl benzyl phthalate; tetramethyl axa onononyl benzyl phthalate;
Bertzoates:
dipropylene glycol dibenzoate;
diethylene glycol dibenzoate;

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50/50 blend dipropylene glycol dibenzoate and diethylene glycoF dibenzoate;
1,4 cyclohexane dimethanol dibenzoate; glyceryl tribenzoate; cumyl phenyl benzoate; neopentyt glycol dibenzoate; pentaerythritol tetabenzoate;
Phosphates:
butyl phenyl diphenyt phosphate -TCP, tricresyl phosphate; 2 ethylhexyl diphenyl phosphate;-isodecyl diphenyl phosphate; C12, C16 alkyl diphenyl phosphate; isopropyiated triphenyl phosphate -
Polyglycols: Polyethylene glycols; Polypropylene glycols.
Particularly preferred plasticizers have- high thermal stability, and include.- ,p-t-butyphenyl diphenyl phosphate; butyl benzyl phthalate; 7-{2,6,6,8-tetramethyl-4-oxa-3-oxononyl) benzyl phthalate; C7/C9 alkyl benzyl phthalate; 2-ethythexyl diphenyl phosphate; and isodecyl dipbenyl- phosphate.
Optionally, the- alkali-solubte support material B may contain oflier components as well; such as filler materials. For example, inert fillers may be selected from a polymer filler group consisting of calcium carbonate, magnesium carbonate, glass spheres, graphite, carbon black, carbon fiber, glass fiber, talc,

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wollastonite, mica, alumina; silica, kaolin, whiskers and silicon carbide. Inorganic fillers such as soluble salts may also be used.
Techniques conventional in polymer chemistry are used to compound the component materials into alkali-soluble support material B. The formulation may be molded into rods, pellets or other shapes for use in the extrusion apparatus, or it may be used directly in' the apparatus without prior solidification. Alternatively, the mixture may be solidified and then granulated, for supply to the extrusion apparatus in granulated form. For use in the modeling process shown and described herein, a. granulated feedstock composition is processed through conventional extrusion apparatus to form continuous flexible filaments. Desirably these-filaments- are wound in-continuous lengths on a spool and dried. Alkali-soluble support material B in filament form is supplied to the extrusion apparatus 10 as, described above The filament 20 is typicaily of a very small. diameter, on the order of 0.070 inches, and may be as small as 0.001 inches in diameter.
EXAMPLES
• The present-invention is more particularly described in the following examples that are intended as illustrations only, since numerous modifications and-variationsaattthmsthe scope of the present, invention will be apparent to those-skilled in the art; Unless otherwise noted, all parts, percentages, and ratios reported in the. following examples are on a. weight basis,, and all reagents used in the examples were obtained, or are available from general chemical suppliers such as, the.Sigma Atdrich Chemical Company of Saint Louis MI, or may be synthesized by conventional techniques. EXAMPLE I
The alkali-soluble thermoplastic material contains 74% of the base polymer and 26% of butyl phenyl diphenyl phosphate plasticizer. The base polymer consists of a higher and a lower

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molecular weight copolymer of methacrylic acid, and methyl methacrylate: The base polymer contains- roughty 50% of the higher molecular weight copolymer and 50% of the lower molecular weight copolymer, plus or minus 5% of each. Each copolymer contains a 1:2 weight percent ratio of methacrylic acid to methyl methacrylate. The higher molecular weight copolymer is. characterized by a high viscosity (low melt flow), and the low molecular weight copofymer is characterized by a low viscosity (high melt flow). Melt flow of the copolymers is measured by plasticizing each copolymer separately with 26. weight percent of the butyl phenyl dipnenyl phosphate, plasticizer. The melt flow index of the plastieized high molecular weight, copolymer is in the range- of 0.4-grams/10 minutes to 0.8 grams/10 minutes, as measured pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. The melt flow index of the plasfjcized low molecular, weight copolymer is in the range of 28 grams/10 minutes to 35 grams/10 minutes. The resulting thermoplastic composition, has a melt flow index of 5 grams/10 minutes to 6.5 grams/10 minutes and a glass transition temperature of about 90°C.
The alkali-soluble thermoplastic material is processed into a 0.070 inch diameter filament and wound on a spool. The filament is fed to a Stratasys FDM® 1650 or a Stratasys FDM© 2000 benchtop. model machine. The molten alkali soluble thermoplastic material is extruded from a liquifier having a temperature of 200°C into a 70°C build envelope onto a polyurethane foam base. The extruded alkali-soluble thermoplastic material has a road width of about 0.020. inchesto about- 0.040 inches and a road height (slice. interval) of about 0.007 inchesto about 0.-020inches. A model is built from ABS thermoplastic having a glass transition temperature of 104°C, using the alkali-soluble thermoplastic material to form supports. The model with the attached supports is placed into an ultrasonic cleaning bath (having a scanning frequency of 25-27 Hertz),

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containing an alkaline aqueous solution of -approximately 98.7 weight percent water, 0.85 weight percent water softener; 0.30 weight percent pH adjuster and 0.15 weight percent surfactant, resulting in a pH of 11 to 13. The bath temperature is set to 70°C (the bath temperature must. remain lower than the glass transition temperature of modeling materiaf A), fn two hours time or less the supports are dissolved.
An alternative base polymer formulation, combines the
higher molecular weight 1:2 copolymer of methacrylic acid and methyl
methacrylate with a lower molecular weight copolymer containing 40%
methacrylic acid and .60% butyl methacrytate.- A further alternative
base polymer formulation uses acrylic acid as the first comonomer.
The further alternative was found, unacceptable- for use in the-
Stratasys FDM® modeling machines, however, as it results in a base
polymer having a tower glass transition temperature- lower than the
build envelope temperature of the machines.
EXAMPLE II
The alkali-soluble thermoplastic material contains 79%. (+/-5%) of the base polymer and 21% (+/-5%) of butyl phenyl diphenyl phosphate plasticizer. The base polymer consists of a 1:1 weight percent ratio of methacrylic acid to methyl methacrylate, having a molecular weight of 135,000 grams/mole Prior to compounding the base polymer with, the- plasticizer, the base polymeris heated in a 220°C oven at low pressure torrid the polymer of water. Heating at low pressure for 10-15 hours was found, sufficient to dry the base polymer. The resultant dry polymer is -in the form of granules, which are fed into a compounder with the-plasticizer in a known--manner. The resulting alkali soluble thermoplastic material has a melt flow. index in the range of 5 grams/10 minutes to 6.5 grams/10 minutes, as measured pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C. The glass transition onset temperature of the alkali-soluble.

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thermoplastic material is about 10.1:5°C and the glass transition peak temperature is about 111°C.
As in Example I above, the alkali-soluble thermoplastic material is processed into a 0.070 inch diameter filament and wound on a spool. The filament is fed to a Stratasys FDM® 1650 or a Stratasys FDM® 2000 benchtop model machine.- Molten alkali-soluble thermoplastic material is extruded from a liquifier having a temperature of 235°C into a build envelope having a temperature of 70°C to 80°C, onto a polyurethane foam base. The extruded alkali-soluble thermoplastic material has a road width of about 0.020 inches to about 0.040 inches and a road height (slice interval) of about 0.007 inches to about 0.020inches. A model is built from ABS thermoplastic -having a. glass transition temperature of 104°C, using the alkali-soluble thermoplastic material to form supports. To dissolve the supports, the model is placed into an ultrasonic cleaning, bath set to 70°C and having a scanning frequency of 25-27 Hertz. containing an alkaline aqueous solution of approximately 98.7% water, 0.85% water softener, 0.30% pH adjuster, and 0.15% surfactant In two hours time or less the supports are dissolved. The alkali-soluble thermoplastic material according to this example exhibits thermal properties, mechanical strength, viscosity, adhesion, solubility and processing- characteristics suitable for three-dimensional modeling on the Stratasys filament-feed benchtop machines. EXAMPLE III
The alkali-soluble, thermoplastic material has the same composition as. in Example II above,, but in this example the base polymer is not heated to release moisture. The alkali-soluble thermoplastic material is processed and extruded from a Stratasys FDM® machine as in Example II, and deposited to form a support structure for a model built of ABS thermoplastic. In this example, the alkali-soluble thermoplastic material exhibited a greater amount of

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"ooze" from the extrusion heat than is desirable, but otherwise exhibited characteristics suitable for three-dimensionai modeling. The "ooze" is attributable to water present in the composition. If used in a modeling system wherein the material dispenser has a positive cut-off mechanism, the "ooze" effect exhibited- in the- Stratasys FDW® machine would not occur and the material according to this' Example III could be effectively utilized. EXAMPLE IV
Samples of alkali-soluble thermoplastic materials of the present invention were created with varying concentrations of. plasticizer to compare the effects of the plasticizer on the glass transition temperatures and the melt flow indexes. The base polymers and the plasticizers used were the same as described in Example I Table 1 provides the weight percent concentratfons of the alkali-soluble thermoplastic materials of Examples, IV(A) - Examples IV(M). As shown, the concentration of plasticizer was varied between the samples. Table 1 also provide the corresponding glass transition temperatures (Tg) and the melt flow indexes (MR) of the alkali-soluble thermoplastic materials of Examples IV(A) — Examples IV(M). The melt flow indexes were tested pursuant to ASTM D1238 under a 1.2 kilogram load at 160°C, 230°C, or.270°C.

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TABLE 1

Composition Weight Percent Base Polymer (*) Weight Percent Plasticizer (*) Tg (°C) MFI (160°C) MFI (230°C) MR (270°C)
Example IV{A) 100 0 160
Example IV(B) 98 2 156 1.1
Example IV(C) 97 3 t54 1.2
Example IV(D) 95 4 147 1.6
Example IV(E) 95 5 145 2.5
Example IV(F) 93 7 142 3.4
Example IV(G) 90 - 10 134 6.0
Example IV(H) 83 17 116 1.7
Example IV(I) 81 19 111 2.3
Example IV(J). ¦79 21 . 109 3.0
Example IV(K) 75 25 100 6.2
Example IV(L) 65 35 74 35.0
Example IV(M) 55 45 49 5.1
(*) Based of the total weight of the alkali-soluble thermoplastic material.
The data in Table 1 illustrates the effects of the plasticizer concentration err the glass transition" temperature and the melt flow.index of the alkali-soluble thermoplastic materials.. In general, as the concentrations of plasticizer in the alkali-soluble thermoplastic materials increase, the gfass transition temperatures decrease and the melt flow indexes increase. As such, varying the plasticizer concentration provides a trade-off between the glass transition temperature and the melt flow index..
For the base polymer and plasticizer used-for Examples IV(A) - Examples IV(M), the glass transition temperatures ranged from about 49°C (45% plasticizer) to about 160°C (no plasticizer}, and were generally inversely linear to the concen tration of plasticizer. As discussed above, the alkali-soluble support materials of the present invention desirably exhibit glass transition temperatures at feast 10°C above the build envelope temperatures. As such, when using high build envelope temperatures (e.g., 100°C or higher), alkali-soluble thermoplastic materials with low concentrations of plasticizer are

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preferred (e.g., 25% or less) to allow the alkali-soluble thermoplastic materials to exhibit higher glass transition temperatares.
With respect to the melt flow, index tested at 230°C, the data in Table 1 shows that the melt flow index increases generally in an exponential manner relative to the concentration of plasticizer. An increase from 25% to 35% plasticizer caused the melt flow index far increase from about 6 grams/10 minutes to about 35 grams/10 minutes. As discussed above, a melt flow index ranging from about 1 gram/10 minutes to about 10 grams/10 minutes is preferred. As such, a melt flow index of about 6 grams/10. minutes is considered . acceptable conditions for extruding the material. However, a melt flow index of about 35 grams/10 minutes may cause the desired physical properties to potentially deteriorate.
As shown in Table 1, plasticizer concentrations of about 25% or less (Examples. IV(A) — Examples IV(K)) provide glass. transition temperatures of about 100C or greater; and melt flow . indexes of about 6 grams/10 minutes or less at 230°C. Such plasticizer concentrations provide acceptable physical characteristics "... forthe alkali-soluble thermoplastic materials of the present invention.
Although the present invention has been described with reference to preferred embodiments,, workers skilled in- the art will recognize that changes may be. made in form-and detail without departing from the spirit and scope of the invention. For. example, it will be appreciated that innumerable modifications may be made to the modeling process. It will .further be appreciated that various modifications may. be made to the. composition .Also, the thermoplastic material, of the present invention could be used to an alkali-soluble three-dimensionar object having usefulness in various molding processes. For example, the alkali-soluble material can form a dissolvable master core in a cast or injection process. The alkali-soluble material can likewise be used to create a mold (by deposition

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modeling or otherwise), which mold can later be dissolved out of an object formed by molding processes.

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CLAIMS:
1. A composition for making a three-dimensional object, the
composition comprising a plasticizer and a base polymer, the base
polymer comprising a carboxylic acid, wherein the composition is
soluble in an alkaline solution.
2. The composition of claim 1, wherein the plasticizer
constitutes from about 0.01% to about 50.0% by weight of the
composition, based on a total weight of the-composition.
3. The composition of claim 2, wherein the plasticizer
constitutes from about 5.0% to about- 25.0% by weight of the
composition, based on the a total weight of the composition.
4. The composition of claim 1, wherein the plasticizer is
selected from a group consisting of p-t-butylphenyl diphenyl
phosphate; butyl benzyl phthalate; 7-(2,6,6,S-tetramethyI-4-oxa-3-
oxononyl) benzyl phthalate; C7/C9-alkyl benzyl phthalate; 2-ethythexyl
diphenyl phosphate; isodecyl diphenyl phosphate,, and combinations
thereof.
5. The composition of claim1, wherein the carboxylic acid -
comprises methacrylic acid.
6. The composition of claim 5, wherein the carboxylic acid
constitutes from about 15.0% to about 60.0% by weight of the base
polymer, based on a total weight of the base polymer.
7. The composition of claim 1, wherein the base polymer
further comprises an alkyl methacrylate.
8. The composition of claim 7, wherein the alkyl
methacrylate comprises a methyl methacrylate:
9. The cornposition of claim 1, wherein the composition
exhibits a glass transition temperature ranging from of about 49°C to
about160°C.
10. The composition of claim 1, wherein the composition
exhibits a melt flow index ranging from of about 1 gram/10 minutes to

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about .10 grams/10 minutes when tested pursuant to ASTM D1238 under a 1.2 kilogram load at230°C.
11. The composition of claim 10, wherein the composition
exhibits a melt flow index ranging from of about 5 grams/10 minutes to
about 10 grams/10 minutes when tested pursuant fa ASTM D1238
under a 1.2 kilogram load at 230°C.
12. A composition for making a three dimensional object, the
composition comprising a carboxylic acid-containing polymer, wherein
the composition is soluble in an alkaline solution, and wherein the
composition exhibits a melt flow index of about 10. grams/10 minutes
or less when tested pursuant to ASTM D1238 under a 1.2 kilogram
load at 230°C.
13. The composition of claim 12 further comprising a
plasticizer.
14. The composition of claim 13 wherein the plasticizer
constitutes about 25.0% by weight of the composition or less,based
on a total weight of the composition.
15. The composition of claim 12, wherein the composition
exhibits a glass transition temperature of about 100°C or greater.
16. The composition of claim 12, wherein the composition
exhibits a melt flow index ranging from of about 5 grams/10 minutes to
about 10. grams/10 minutes when tested pursuant to ASTM D1238
under a 1.2 kilogram load at 230°C.
17. The composition of claim. 12, wherein the carboxylic acid
comprises methacrylic acid.
18. The composition of claim 42, wherein the base polymer
further comprises an alkyl metnacrylate;
19. The composition of claim 18, wherein the alkyl
methacrylate comprises a methyl methacrylate.
20. The composition of claim 18, wherein the carboxylic acid
constitutes from about 15.0% to about 60.0% by weight of the

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carboxylic acid and the alkyyl methacrylate, based on a total weight of the carboxylic acid and the alky! methacrylate.
21. The composition of claim 18, wherein the carboxylic acid
and the alkyl methacrylate are polymerized-
22. A method of malting a three-dimensional article, the.
method comprising:
depositing a composition comprising, a. base polymer-derived from a carboxylic acid, wherein the composition is soluble in an alkaline solution, and wherein the composition exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM. D1238 under a T.2 kilogram load at 230°C; and
allowing the" composition to solidify.
23. The method of claim 22, wherein the composition is
deposited and solidified in a plurality of steps so as to make a plurality
of layers, wherein the layers define the three-dimensional article.
24. The method of claim '22, wherein the composition further
comprises a plasticizer.
25. The method of claim 24, wherein the plasticizer
constitutes about 25.0%. by weight of the composition or less, based
on a total weight of the composition.
26. The method of claim 24, wherein the composition is
deposited in a build envelope that exhibits a build envelope.,
temperature and wherein the plasticizer is concentrated- in the
composition at effective levels to allow the composition to exhibit a
glass transition temperature greater than the build envelope
temperature.
27. The method of claim 24, wherein the plasticizer
constitutes about 25.0% by weight of the composition or less, based
on a total weight of the composition. •

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28. The method of claim 27, wherein the composition
exhibits a glass transition temperature of about 100°C or greater.
29. The method of claim 27, wherein the composition
exhibits a melt flow index ranging from of about 5 grams/10 minutes to
about 10 grams/10 minutes when tested pursuant to ASTM D1238
under a 1.2 kilogram load at 230°C.
30. The composition of claim 22, wherein the carboxylic acid
comprises methacrylic acid.
31. The composition of claim 22, 'wherein the base polymer
is further derived from an alkyl methacrylate.
32. The composition of claim 31, wherein the. alkyl
methacrylate comprises a methyl methacrylate.
33. In a process for making a three-dimensional object.by
dispensing solidifiable modeling material in a predetermined pattern so
as to define the three-dimensional object in coordination with
dispensing solidifiable support material so as to define a support
structure for the three-dimensional object, the support structure
thereby having portions thereof in contact with the object, the
improvement comprising:
forming at least, those portions of the support structure contacting the object from a thermoplastic material comprising a carboxylic acid-containing polymer, wherein the composition is soluble in an alkaline solution, and wherein the composition exhibits: a melt flow index of about 10. grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C.
34. The process of claim 33, wherein the thermoplastic
material further comprises a plasticizer constituting from about 0.01%

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to about 50.0% by weight of the thermoplastic material, based on a total weight of the thermoplastic material.
35. An additive process for making three-dimensional
objects, comprising:
5 dispensing an alkali-insoluble modeling material in a
predetermined pattern defining a three dimensional-object having overhanging portions that require support during formation; and dispensing a support material in the space beneath the
10 overhanging- portions of the three-dimensional
object in coordination with the dispensing of the modeling material to form a three-dimtensional support structure for the object, the support material comprising a carboxylic acid-containing
15 polymer wherein the composition is soluble in an
alkaline-solution, and wherein the composition' exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at 230°C;
20 whereby the support material may be dissolved from the
three-dimensional object by application of an alkaline solution.
36. The process of claim 35; wherein the support material
further comprises a plasticizer;
37. The process of claim 35, wherein the support material
exhibits a glass transition temperature of about 100°C or greater;
38. In a process for making three-dimensional objects by
depositing solidifiable material onto a base, the improvement comprising:
30 providing as the solidifiable material a carboxylic acid-
containing polymer, wherein the composition is

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soluble in an alkaline solution, and wherein the . composition exhibits a melt flow index of about 10 grams/10 minutes or less when tested pursuant to ASTM D1238 under a 1.2 kilogram load at230°C.

The present invention is a composition for making a three dimensional object. The composition comprises a plas-ticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solulion.

A FEEDSTOCK FOR MAKING A SUPPORT STRUCTURE FOR A THREE-DIMENSIONAL OBJECT USING AN ADDITIVE PROCESSING TECHNIQUE

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