Stabilizing liquid functional material for three- dimensional (3D) printing

Patent metadata

Field	Value
Publication number	US-10875240-B2
Application number	US-201515735934-A
Country	US
Kind code	B2
Filing date	Jul 24, 2015
Priority date	Jul 24, 2015
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

A stabilizing liquid functional material (SLFM) for 3D printing includes ceramic nanoparticles in an amount ranging from about 0.25% to about 5% by weight based on a total SLFM weight and silica nanoparticles present in an amount ranging from about 0.1% to about 10% by weight based on the total SLFM weight. The ceramic nanoparticles have a particle size ranging from about 5 nm to about 50 nm. The silica nanoparticles have a particle size ranging from about 10 nm to about 50 nm. The ceramic nanoparticles and the silica nanoparticles are different in composition and/or morphology. An electromagnetic radiation absorber is present in an amount ranging from about 1% to about 10% by weight based on the total SLFM weight. An organic solvent is present in an amount from about 5% to about 50% by weight based on the total SLFM weight. The SLFM includes a balance of water.

First claim

What is claimed is:

1. A three-dimensional (3D) printing method, comprising:
applying a first layer of a build material;
patterning an initial part layer by selectively applying, with an inkjet printhead, a stabilizing liquid functional material on at least a portion of the first layer, the stabilizing liquid functional material including:
a first ceramic nanoparticle in an amount ranging from about 0.25% to about 5% by weight based on a total weight of the liquid functional material, wherein the first ceramic nanoparticle is selected from the group consisting of silica particles, alumina particles, zinc oxide particles, iron oxide particles, titanium oxide particles, copper oxide particles, cobalt oxide particles, indium oxide particles, zirconium oxide particles, silver oxide particles, and combinations thereof, wherein the first ceramic nanoparticle has a particle size ranging from about 5 nm to about 50 nm;
a second ceramic nanoparticle in an amount ranging from about 0.1% to about 10% by weight based on the total weight of the liquid functional material, the second ceramic nanoparticle being different from the first ceramic nanoparticle, wherein the second ceramic nanoparticle is a discrete silica particle with a diameter ranging from about 10 nm to about 50 nm, or fibrous silica with a diameter ranging from about 10 nm to about 50 nm and a length ranging from about 50 nm to about 250 nm, or chain silica with each particle in the chain having a diameter ranging from about 10 nm to about 50 nm and a length of the chain ranging from about 100 nm to about 250 nm;
an electromagnetic radiation absorber in an amount ranging from about 1 to about 10% by weight based on the total weight of the liquid functional material;
an organic solvent in an amount ranging from about 5% to about 50% by weight based on the total weight of the liquid functional material; and
a balance of water;
wherein the stabilizing liquid functional material excludes a binder, and wherein the stabilizing liquid functional material is a non-Newtonian inkjet ink whose viscosity increases within about 1 second to about 30 seconds of exiting the inkjet printhead;

applying a second layer of the build material;
patterning a perimeter of an additional part layer by selectively applying the stabilizing liquid functional material on a portion of the second layer; and
exposing the first and second layers having the stabilizing liquid functional material respectively applied thereon to electromagnetic radiation, whereby the portion of the first layer at least partially fuses to form the initial part layer and the portion of the second layer at least partially fuses to form the perimeter of the additional part layer.

2. The 3D printing method as defined in claim 1 wherein:
prior to the exposing, the method further comprises patterning a remainder of the additional part layer by selectively applying a penetrating liquid functional material on at least an other portion of the second layer within the perimeter; and
during the exposing, the other portion of the second layer at least partially fuses to form the remainder of the additional part layer.

3. The 3D printing method as defined in claim 2 wherein the penetrating liquid functional material includes:
a first metal oxide particle having a particle size up to 10 nm, the first metal oxide particle present in an amount ranging from about 5% to about 15% by weight based on a total weight of the penetrating liquid functional material;
a second metal oxide particle having a particle size ranging from about 20 nm to about 50 nm, the second metal oxide particle present in an amount ranging from about 0.25% to about 10% by weight based on the total weight of the penetrating liquid functional material;
an electromagnetic radiation absorber in an amount ranging from about 1% to about 10% by weight based on the total weight of the penetrating liquid functional material;
an organic solvent in an amount from about 5% to about 50% by weight based on the total weight of the penetrating liquid functional material;
a surfactant; and
a balance of water.

4. The 3D printing method as defined in claim 2 wherein the exposing of the first layer, having the stabilizing liquid functional material selectively applied thereon, to the electromagnetic radiation and the exposing of the second layer, having the stabilizing liquid functional material and the penetrating liquid functional material selectively applied thereon, to the electromagnetic radiation occur simultaneously.

5. The 3D printing method as defined in claim 2 wherein:
the exposing of the first layer to the electromagnetic radiation occurs after the stabilizing liquid functional material is selectively applied thereon and before the second layer of the build material is applied; and
the exposing of the second layer to the electromagnetic radiation occurs after the stabilizing liquid functional material and the penetrating liquid functional material are selectively applied thereon.

6. The 3D printing method as defined in claim 1 wherein the stabilizing liquid functional material has a pH ranging from about 9 to about 12 and a conductivity ranging from about 100 μS/cm to about 2000 μS/cm, and wherein the selectively applying of the stabilizing liquid functional material is accomplished via inkjet printing.

7. A three-dimensional (3D) printing method, comprising:
applying a first layer of a build material;
patterning an initial part layer by selectively applying a stabilizing liquid functional material on at least a portion of the first layer, the stabilizing liquid functional material including:
a first ceramic nanoparticle in an amount ranging from about 0.25% to about 5% by weight based on a total weight of the stabilizing liquid functional material, the first ceramic nanoparticle is selected from the group consisting of silica particles, alumina particles, zinc oxide particles, iron oxide particles, titanium oxide particles, copper oxide particles, cobalt oxide particles, indium oxide particles, zirconium oxide particles, silver oxide particles, and combinations thereof, wherein the first ceramic nanoparticle has a particle size ranging from about 5 nm to about 50 nm;
second ceramic nanoparticle in an amount ranging from about 0.1% to about 10% by weight based on the total weight of the stabilizing liquid functional material, the second ceramic nanoparticle being different from the first ceramic nanoparticle, wherein the second ceramic nanoparticle is a discrete silica particle with a diameter ranging from about 10 nm to about 50 nm, or fibrous silica with a diameter ranging from about 10 nm to about 50 nm and a length ranging from about 50 nm to about 250 nm, or chain silica with each particle in the chain having a diameter ranging from about 10 nm to about 50 nm and a length of the chain ranging from about 100 nm to about 250 nm;
an electromagnetic radiation absorber in an amount ranging from about 1 to about 10% by weight based on the total weight of the stabilizing liquid functional material;
an organic solvent in an amount from about 5% to about 50% by weight based on the total weight of the stabilizing liquid functional material; and
a balance of water;
wherein the stabilizing liquid functional material excludes a binder, and wherein the stabilizing liquid functional material is a non-Newtonian inkjet ink whose viscosity increases within about 1 second to about 30 seconds of exiting the inkjet printhead;

applying a second layer of the build material;
patterning an additional part layer by selectively applying the stabilizing liquid functional material or a penetrating liquid functional material on at least a portion of the second layer; and
exposing the first layer having the stabilizing liq

Assignees

• Hewlett Packard Development Co

Inventors

• Abbott Jr James Elmer
• Adamic Raymond
• Champion David A

Classifications

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• Y02P10/25

  Process efficiency · CPC title