Three-dimensional (3D) printing with a sintering aid/fixer fluid and a liquid functional material

Patent metadata

Field	Value
Publication number	US-11020874-B2
Application number	US-201615771134-A
Country	US
Kind code	B2
Filing date	Feb 25, 2016
Priority date	Feb 25, 2016
Publication date	Jun 1, 2021
Grant date	Jun 1, 2021

Abstract

In an example of a three-dimensional (3D) printing method, a ceramic build material is applied. A liquid functional material, including an anionically stabilized susceptor material, is applied to at least a portion of the ceramic build material. A sintering aid/fixer fluid, including a cationically stabilized amphoteric alumina particulate material, is applied to the at least the portion of the ceramic build material. The applied anionically stabilized susceptor material and the applied cationically stabilized amphoteric alumina particulate material react to immobilize the anionically stabilized susceptor material, thereby patterning the at least the portion of the ceramic build material.

First claim

What is claimed is:

1. A three-dimensional (3D) printing method, comprising:
applying a ceramic build material;
applying a liquid functional material, including an anionically stabilized susceptor material, to a portion of the ceramic build material, wherein the anionically stabilized susceptor material is selected from the group consisting of a carbon black particle having negatively charged groups at a surface of the carbon black particle, a carbon black particle having a negatively charged polymeric dispersant absorbed to a surface thereof, a ferromagnetic metal oxide particle having an anionic dispersing species absorbed to a surface thereof, a semiconductor or conductive oxide particle having an anionic dispersing species absorbed to a surface thereof, and combinations thereof, and
applying a sintering aid/fixer fluid, including a cationically stabilized amphoteric alumina particulate material, to the portion of the ceramic build material,
the applied anionically stabilized susceptor material and the applied cationically stabilized amphoteric alumina particulate material reacting to immobilize and prevent the spreading of both materials outside the portion, thereby patterning the portion of the ceramic build material.

2. The 3D printing method as defined in claim 1 wherein the liquid functional material is applied before the sintering aid/fixer fluid.

3. The 3D printing method as defined in claim 1 wherein the liquid functional material and the sintering aid/fixer fluid are applied simultaneously from separate applicators.

4. The 3D printing method as defined in claim 1 wherein the application of the ceramic build material, the liquid functional material, and the sintering aid/fixer fluid forms a first layer of a green body, and wherein the method further comprises heating the green body using microwave radiation, radio frequency radiation, or thermal energy, thereby sintering the ceramic build material and the applied cationically stabilized amphoteric alumina particulate material of the green body to form a part.

5. The 3D printing method as defined in claim 1 wherein the application of the ceramic build material, the liquid functional material, and the sintering aid/fixer fluid forms a first layer of a green body, and wherein the method further comprises forming a second layer of the green body by:
applying additional ceramic build material to the first layer of the green body;
applying the liquid functional material to a portion of the additional ceramic build material; and
applying the sintering aid/fixer fluid to the portion of the additional ceramic build material.

6. The 3D printing method as defined in claim 5 , further comprising forming subsequent layers of the green body by repeating the application of the ceramic build material, the liquid functional material, and the sintering aid/fixer fluid in each subsequent layer.

7. The 3D printing method as defined in claim 6 , further comprising heating the green body using microwave radiation, radio frequency radiation, or thermal energy, thereby sintering the ceramic build material of the green body to form a part.

8. The 3D printing method as defined in claim 1 wherein:
the ceramic build material includes particles having a particle size ranging from about 100 nm and about 500 μm;
the cationically stabilized amphoteric alumina particulate material has a particle size of less than 100 nm; and
the applied cationically stabilized amphoteric alumina particulate material fills at least some voids between the ceramic build material.

9. The 3D printing method as defined in claim 1 wherein the sintering aid/fixer fluid has a pH ranging from about 3.5 to about 5.0.

10. The 3D printing method as defined in claim 9 , further comprising forming the sintering aid/fixer fluid by milling a water-dispersible amphoteric alumina powder in an aqueous vehicle having the pH ranging from about 3.5 to about 5.0.

11. The 3D printing method as defined in claim 1 wherein:
the ferromagnetic metal oxide particle is selected from the group consisting of Fe 3 O 4 , a complex ferrite, and combinations thereof; and
the anionic dispersing species absorbed to the surface of the ferromagnetic metal oxide particle is selected from the group consisting of multi-carboxylic organic acids, phosphate ions, and water-soluble polymers containing carboxylic groups or sulfo groups.

12. A three-dimensional (3D) printing method, comprising:
forming a green body with multiple layers, each of the multiple layers being formed by:
applying ceramic build material; and
patterning the ceramic build material by:
applying a liquid functional material, including an anionically stabilized susceptor material selected from the group consisting of a carbon black particle having negatively charged groups at a surface of the carbon black particle, a carbon black particle having a negatively charged polymeric dispersant absorbed to a surface thereof, a ferromagnetic metal oxide particle having an anionic dispersing species absorbed to a surface thereof, a semiconductor or conductive oxide particle having an anionic dispersing species absorbed to a surface thereof, and combinations thereof, to a portion of the ceramic build material; and
applying a sintering aid/fixer fluid, including a cationically stabilized amphoteric alumina particulate material, to the portion of the ceramic build material,
the applied anionically stabilized susceptor material and the applied cationically stabilized amphoteric alumina particulate material reacting to immobilize and prevent the spreading of both materials outside the portion, and the applied cationically stabilized amphoteric alumina particulate material filling at least some voids between the ceramic build material; and

heating the green body using microwave radiation, radio frequency radiation, or thermal energy, thereby sintering the ceramic build material and the applied cationically stabilized amphoteric alumina particulate material of the green body to form a part.

13. A three-dimensional (3D) printing system, comprising:
a supply of ceramic build material;
a build material distributor;
a supply of a liquid functional material including an anionically stabilized susceptor material selected from the group consisting of a carbon black particle having negatively charged groups at a surface of the carbon black particle, a carbon black particle having a negatively charged polymeric dispersant absorbed to a surface thereof, a ferromagnetic metal oxide particle having an anionic dispersing species absorbed to a surface thereof, a semiconductor or conductive oxide particle having an anionic dispersing species absorbed to a surface thereof, and combinations thereof;
a supply of a sintering aid/fixer fluid including a cationically stabilized amphoteric alumina particulate material;
respective applicators for selectively dispensing the liquid functional material and the sintering aid/fixer fluid;
a controller; and
a non-transitory computer readable medium having stored thereon computer executable instructions to cause the controller to:
utilize the build material distributor to dispense a layer of the ceramic build material; and
utilize the applicators to simultaneously or sequentially dispense the liquid functional material and the sintering aid/fixer fluid onto a portion of the layer of the ceramic build material such that at least some of the anionically stabilized susceptor material reacts with at least some of the cationically stabilized amphoteric alumina particulate material to immobilize and prevent the spreading of both materials outside the portion.

14. The 3

Assignees

• Hewlett Packard Development Co

Inventors

• Abbott Jr James Elmer
• Kasperchik Vladek
• Flynn Joshua

Classifications

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• C04B2237/363

  Carbon · CPC title

• C04B2237/34

  Oxidic · CPC title

• C04B2237/341

  Silica or silicates · CPC title

• C04B2235/9661

  Colour · CPC title