Additive manufacturing material for powder rapid prototyping manufacturing

Patent metadata

Field	Value
Publication number	US-10710157-B2
Application number	US-201616064774-A
Country	US
Kind code	B2
Filing date	Dec 20, 2016
Priority date	Dec 22, 2015
Publication date	Jul 14, 2020
Grant date	Jul 14, 2020

Abstract

A molding material is provided which, despite containing a ceramic, enables efficient molding for producing high-density molded articles. The present invention provides a molding material to be used in powder laminate molding. This molding material contains a first powder which contains a ceramic, and a second powder which contains a metal. Further the first powder and the second powder are bonded by sintering to configure granulated sintered particles. The granule strength of the granulated sintered particles is greater than 1 MPa and less than 10,000 MPa.

First claim

The invention claimed is:

1. A method for producing a three-dimensional manufactured article, comprising:
(a) preparing an additive manufacturing material comprising a first powder containing a ceramic and a second powder containing a metal, wherein the first powder and the second powder are bound by sintering to form granulated sintered particles in which primary particles of the first powder and primary particles of the second powder are three-dimensionally bound through voids, and the granulated sintered particles have a granule strength of above 1 MPa and less than 10000 MPa;
(b) forming a thin layer of the additive manufacturing material; and
(c) applying energy to the formed thin layer to melt or sinter the additive manufacturing material to obtain a powder solidified layer having a desired cross-sectional shape,
wherein the first powder and the second powder have average particle diameters of 0.1 μm or more and 20 μm or less, and
wherein a proportion of the second powder to the sum of the first powder and the second powder is 10% by mass or more and 90% by mass or less.

2. The method of claim 1 , wherein the granulated sintered particles have a granule strength of 10 MPa or more and 5000 MPa or less.

3. The method of claim 1 , wherein the additive manufacturing material has an average particle diameter of 1 μm or more and 100 μm or less.

4. The method of claim 1 , wherein the first powder includes a carbide ceramic.

Assignees

• Fujimi Inc

Inventors

• Ibe Hiroyuki
• Yamada Junya

Classifications

• B22F1/148

  Agglomerating · CPC title

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/14

  by jetting of binder onto a bed of metal powder · CPC title