Ceramic support structure

Patent metadata

Field	Value
Publication number	US-10022889-B2
Application number	US-201414776007-A
Country	US
Kind code	B2
Filing date	Mar 14, 2014
Priority date	Mar 14, 2013
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

A feedstock material for use as a support material in an additive manufacturing system includes a pre-ceramic material in powder form. The preceramic material comprises calcium carbonate, sodium carbonate, sodium aluminate or combinations thereof. The feedstock material includes a thermoplastic binder having the pre-ceramic material dispersed therein, wherein the pre-ceramic material and the thermoplastic binder are in a filament form. The filament is configured to be melted and extruded to form a support structure for a ceramifable article in a layer by layer manner, wherein the pre-ceramic material is at least about 50% of the feedstock material.

First claim

What is claimed is:

1. A feedstock material for use as a support material in an additive manufacturing system, the feedstock material comprising:
a pre-ceramic material in powder form, the preceramic material comprises calcium carbonate, sodium carbonate, sodium aluminate or combinations thereof; and
a thermoplastic binder having the pre-ceramic material dispersed therein, wherein the pre-ceramic material and the thermoplastic binder are in a filament form;
wherein the filament is configured to be melted and extruded to form a support structure for a ceramifable article in a layer by layer manner, wherein the pre-ceramic material is at least about 50% of the feedstock material.

2. The feedstock material of claim 1 , wherein the thermoplastic binder is a polymeric matrix comprising one or more of polyolefins, polylactic acid polymers, and acrylonitrile butadiene styrene polymers or combinations thereof.

3. The feedstock material of claim 1 , and further comprising one or more of a fluxing materials, a polymer processing additive or combinations thereof.

4. The feedstock material of claim 3 , wherein the fluxing material comprises glass fits having boron trioxide, silicon oxide, zirconium dioxide, lithium oxide, fluorine, titanium dioxide, and combinations thereof.

5. A method of printing a three-dimensional ceramifiable article with an extrusion based additive manufacturing system, the method comprising:
extruding the article in a layer by layer manner with a thermoplastic material containing a ceramifiable powder wherein the ceramificable powder comprises a majority of the thermoplastic material with the additive manufacturing system;
extruding a corresponding support structure in a layer by layer manner with the printing of the layers of the article, wherein the support comprises a feedstock material comprising:
a pre-ceramic material in powder form, wherein the pre-ceramic material has similar melting point to that of the ceramifiable powder to prevent softening of the pre-ceramic material during the ceramification process; and
a polymeric binder, wherein the pre-ceramic material is at least about 50% of the feedstock material.

6. The method of claim 5 , and further comprising heating the three-dimensional ceramifiable article and the corresponding support structure to a first temperature to remove the polymeric binder.

7. The method of claim 6 , and further heating the three-dimensional article and the corresponding support structure to a second temperature that is higher than the first temperature to transform the article and the corresponding support structure into ceramic materials.

8. The method of claim 7 , further comprising subjecting the ceramic article and corresponding support structure to a solvent to remove the support structure from the article.

9. The method of claim 5 , wherein the polymeric binder is a matrix comprising one or more of polyolefins, polylactic acid polymers, and acrylonitrile butadiene styrene polymers or combinations thereof.

10. The method of claim 5 , wherein the pre-ceramic material comprises calcium carbonate, sodium carbonate, sodium aluminate or combinations thereof.

11. The method of claim 8 , wherein the solvent comprises water, carbonated solutions, acidic solutions and combinations thereof.

12. The method of claim 5 , wherein the feedstock material is a filament configured for building a three-dimensional support structure.

13. The method of claim 5 , wherein the feedstock material further comprises one or more of a fluxing materials, a polymer processing additive or combinations thereof.

14. A method of building a three-dimensional article with additive manufacturing comprising:
printing the article wherein the article comprises at least one build layer;
printing a support structure comprising at least one support layer, the support structure configured to provide support to the article, wherein the support structure comprises a feedstock material comprising a pre-ceramic material and a polymeric binder, wherein the pre-ceramic material is at least about 50% of the feedstock material;
heating the article and the support structure to a temperature to remove the polymeric binder through thermal degradation;
sintering the article and the support material at a second temperature that is higher than the first temperature to cause ceramification of the article and the support structure, and
subjecting the ceramic article and the ceramic support structure to a solvent to remove the ceramic support structure from the article.

Assignees

• Stratasys Inc

Inventors

• Demuth Benjamin A
• Pawloski Adam R

Classifications

• C04B2235/442

  Carbonates · CPC title

• C04B35/634

  Polymers (C04B35/636 takes precedence) · CPC title

• B28B11/243

  Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence) · CPC title

• C04B35/62695

  Granulation or pelletising (devices for shaping artificial aggregates from ceramic mixtures B28B1/004) · CPC title

• D01F1/02

  Addition of substances to the spinning solution or to the melt (addition of substances to viscose D01F2/08) · CPC title