Three-dimensional (3D) printing

Patent metadata

Field	Value
Publication number	US-10647053-B2
Application number	US-201616072123-A
Country	US
Kind code	B2
Filing date	May 12, 2016
Priority date	May 12, 2016
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

In an example of a three-dimensional (3D) printing method, a polymeric build material is applied. A fusing agent is selectively applied on at least a portion of the polymeric build material. A mechanical tailoring agent is selectively applied on at least a region of the portion. The polymeric build material is exposed to radiation, thereby fusing the at least the portion of the polymeric build material in contact with the fusing agent to form a layer. The mechanical tailoring agent forms a composite layer in the at least the region, and the composite layer has a different mechanical property than that of an area of the layer not in contact with the mechanical tailoring agent.

First claim

What is claimed is:

1. A three-dimensional (3D) printing method, comprising:
applying a polymeric build material;
selectively applying a fusing agent on at least a portion of the polymeric build material;
selectively applying a mechanical tailoring agent on at least a region of the portion; and
exposing the polymeric build material to radiation, thereby fusing the at least the portion of the polymeric build material in contact with the fusing agent to form a layer;
wherein the mechanical tailoring agent forms a composite layer in the at least the region, and wherein the composite layer has a different mechanical property than that of an area of the layer not in contact with the mechanical tailoring agent.

2. The method as defined in claim 1 wherein:
the composite layer includes all of the layer; or
the composite layer includes less than all of the layer.

3. The method as defined in claim 2 wherein one of:
the composite layer includes less than all of the layer, wherein the selectively applying of the mechanical tailoring agent is accomplished separate from the selectively applying of the fusing agent, and wherein the selectively applying of the fusing agent includes applying a greater amount of the fusing agent to the region of the portion than to a remaining region of the portion; or
the composite layer includes all of the layer and wherein the selectively applying of the fusing agent is accomplished together with the selectively applying of the mechanical tailoring agent.

4. The method as defined in claim 1 wherein one of:
the selectively applying of the fusing agent is accomplished separate from and prior to the selectively applying of the mechanical tailoring agent; or
the selectively applying of the mechanical tailoring agent is accomplished separate from and prior to the selectively applying of the fusing agent.

5. The method as defined in claim 1 wherein the selectively applying of the mechanical tailoring agent is accomplished by thermal inkjet printing or piezoelectric inkjet printing.

6. The method as defined in claim 1 wherein the mechanical tailoring agent is a plasticizer liquid including a plasticizer, and wherein the composite layer has greater ductility than that of the area of the layer not in contact with the mechanical tailoring agent.

7. The method as defined in claim 6 wherein:
the plasticizer liquid includes the plasticizer and a solvent;
the plasticizer is selected from the group consisting of 2-pyrrolidone, dimethyl sulfoxide (DMSO), methyl 4-hydroxybenzoate, dioctyl phthalate, N-methyl-2-pyrrolidone, N-2-hydroxyethyl-2-pyrrolidone, urea, ethylene carbonate, propylene carbonate, lactones, diethylene glycol, triethylene glycol, tetraethylene glycol, decalin, gamma-butyrolactone, dimethylformamide, phenylmethanol, and mixtures thereof; and
the solvent is selected from the group consisting of water, N-2-hydroxyethyl-2-pyrrolidone, 1,6-hexanediol, dimethyl sulfoxide (DMSO), isopropyl alcohol, ethanol, acetone, and mixtures thereof.

8. The method as defined in claim 6 wherein the plasticizer is included in an amount ranging from about 1 wt % to about 100 wt % based on the total wt % of the plasticizer liquid.

9. The method as defined in claim 1 wherein the mechanical tailoring agent is a mechanical reinforcer liquid including a mechanical reinforcer, and wherein the composite layer has greater rigidity than that of the area of the layer not in contact with the mechanical tailoring agent.

10. The method as defined in claim 9 wherein:
the mechanical reinforcer liquid includes the mechanical reinforcer, a solvent, and a dispersant;
the mechanical reinforcer is graphene, carbon black, boron nanomaterial, boron nitride nanomaterial, carbon nanomaterial, silica nanomaterial, alumina nanomaterial, titanium dioxide nanomaterial, glass nanomaterial, montmorillonite nanomaterial, talc nanomaterial, basalt nanomaterial, silicon carbide nanomaterial, metal carbide nanomaterial, silicon nitride nanomaterial, metal nitride nanomaterial, polyaramide nanomaterial, metal nanomaterial, metal alloy nanomaterial, diamond nanomaterial, boron carbide nanomaterial, mica nanomaterial, wollastonite nanomaterial, ceramic nanomaterial, and combinations thereof; and
the solvent is selected from the group consisting of water, 1-(2-hydroxyethyl)-2-pyrrolidinone, 1,6-hexanediol, dimethyl sulfoxide (DMSO), isopropyl alcohol, ethanol, acetone, N-methyl-2-pyrrolidone, dimethyl formamide, cyclohexyl pyrrolidone, and mixtures thereof.

11. The method as defined in claim 9 wherein the mechanical reinforcer is a cross-linking agent.

12. A three-dimensional (3D) printing method, comprising:
applying a polymeric build material;
selectively applying a fusing agent on at least a portion of the polymeric build material;
exposing the polymeric build material to radiation, thereby fusing the at least the portion of the polymeric build material in contact with the fusing agent to form a layer; and
selectively applying a mechanical tailoring agent on at least a portion of the layer, thereby forming a mechanical component on the at least the portion of the layer or preparing the at least the portion of the layer to receive additional build material that will absorb the mechanical tailoring agent.

13. The method as defined in claim 12 , further comprising annealing the at least the portion of the layer in contact with the mechanical tailoring agent.

14. The method as defined in claim 12 wherein the mechanical component is formed, and wherein the method further comprises at least partially embedding the mechanical component by:
applying additional polymeric build material on the layer;
selectively applying the fusing agent on at least a portion of the additional polymeric build material; and
exposing the additional polymeric build material to radiation, thereby fusing the at least the portion of the additional polymeric build material.

15. The method as defined in claim 14 wherein the selectively applying of the fusing agent is accomplished by applying the fusing agent on the at least the portion of the additional build material that does not cover the mechanical component.

Assignees

• Hewlett Packard Development Co

Inventors

• Erickson Kristopher J
• Zhao Lihua
• Tom Howard S
• Hartman Aja
• Zhao Yan
• Fitzhugh Andrew E

Classifications

• B29C64/264

  Arrangements for irradiation · CPC title

• B32B2398/20

  Thermoplastics · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title