Three-dimensional (3D) printing

Patent metadata

Field	Value
Publication number	US-11104029-B2
Application number	US-201615771561-A
Country	US
Kind code	B2
Filing date	Feb 26, 2016
Priority date	Feb 26, 2016
Publication date	Aug 31, 2021
Grant date	Aug 31, 2021

Abstract

In a three-dimensional printing method example, a build material is applied. A first liquid functional material is applied on at least a portion of the build material. The first liquid functional material includes ferromagnetic nanoparticles that are selected from the group consisting of an iron oxide, a ferrite, a combination of the iron oxide and a ferromagnetic metal oxide, and combinations thereof. The build material is exposed to electromagnetic radiation having a frequency ranging from about 5 kHz to about 300 GHz to sinter the portion of the build material in contact with the first liquid functional material.

First claim

What is claimed is:

1. A three-dimensional (3D) printing method, comprising:
applying a build material;
selectively applying, by thermal inkjet printing or piezoelectric inkjet printing, a first liquid functional material including ferromagnetic nanoparticles on at least a portion of the build material, wherein the ferromagnetic nanoparticles are selected from the group consisting of a ferrite, a combination of an iron oxide and a ferromagnetic metal oxide, and combinations thereof; and
exposing the build material to electromagnetic radiation having a frequency ranging from about 5 kHz to about 300 GHz, thereby sintering the portion of the build material in contact with the first liquid functional material;
wherein the build material is a ceramic build material, and wherein the first liquid functional material heats the at least the portion of the ceramic build material to a temperature sufficient to sinter the at least the portion of the ceramic build material, the temperature ranging from about 1400° C. to about 2500° C.

2. The 3D printing method as defined in claim 1 wherein the ferromagnetic nanoparticles are present in the first liquid functional material in an amount ranging from about 0.1 wt % to about 50 wt % based on a total wt % of the first liquid functional material.

3. The 3D printing method as defined in claim 1 wherein the first liquid functional material further includes water, a co-solvent, a surfactant, and a dispersant selected from the group consisting of a) a small molecule anionic dispersant b) a short chain polymer dispersant; or c) a small molecule non-ionic dispersant; or d) a combination of a) or b) with c).

4. The 3D printing method as defined in claim 1 wherein any one or more of:
the iron oxide is iron (II) oxide, iron (III) oxide, or iron (II, III) oxide;
the ferromagnetic metal oxide is cobalt (II) oxide, cobalt (II, III) oxide, manganese (III) oxide, or combinations thereof; or
the ferrite is selected from the group consisting of barium ferrite (BaFe 12 O 19 ), cobalt ferrite (CoFe 2 O 4 ), cobalt-zinc ferrite (Co 0.5 Zn 0.5 Fe 2 O 4 ), nickel ferrite (NiFe 2 O 4 ), nickel-zinc ferrite (Ni 0.5 Zn 0.5 Fe 2 O 4 ), zinc ferrite (ZnFe 2 O 4 ), and complex ferrites.

5. The 3D printing method as defined in claim 1 wherein exposing the build material to the electromagnetic radiation raises a temperature of the portion of the build material in contact with the first liquid functional material to at least 60° C.

6. The 3D printing method as defined in claim 1 wherein the ceramic build material includes metal oxide ceramics, inorganic glasses, carbides, nitrides, borides, or a combination thereof.

7. The 3D printing method as defined in claim 1 , further comprising selectively applying a second liquid functional material on the at least the portion of the build material in contact with the first liquid functional material.

8. The 3D printing method as defined in claim 7 wherein the second liquid functional material includes a dispersion of particles with high microwave radiation absorptivity.

9. The 3D printing method as defined in claim 1 wherein the ferromagnetic nanoparticles comprise the combination of the iron oxide and the ferromagnetic metal oxide.

10. The 3D printing method as defined in claim 9 wherein:
the iron oxide is iron (II) oxide, iron (III) oxide, or iron (II, III) oxide; and
the ferromagnetic metal oxide is cobalt (II) oxide, cobalt (II, III) oxide, manganese (III) oxide, or combinations thereof.

11. A three-dimensional (3D) printing method, comprising:
applying a build material;
selectively applying, by thermal inkjet printing or piezoelectric inkjet printing, a first liquid functional material including ferromagnetic nanoparticles on at least a portion of the build material, wherein the ferromagnetic nanoparticles are selected from the group consisting of a ferrite, a combination of an iron oxide and a ferromagnetic metal oxide, and combinations thereof;
exposing the build material to electromagnetic radiation having a frequency ranging from about 5 kHz to about 300 GHz, thereby sintering the portion of the build material in contact with the first liquid functional material; and
selectively applying a second liquid functional material on the at least the portion of the build material in contact with the first liquid functional material;
wherein the build material is a ceramic build material, wherein the second liquid functional material heats the at least the portion of the ceramic build material to an initial temperature below 500° C., and wherein the first liquid functional material heats the at least the portion of the ceramic build material to a temperature sufficient to sinter the at least the portion of the ceramic build material, the temperature ranging from about 1400° C. to about 2500° C.

12. A three-dimensional (3D) printing method, comprising:
applying a build material;
selectively applying, by thermal inkjet printing or piezoelectric inkjet printing, a first liquid functional material including ferromagnetic nanoparticles on at least a portion of the build material, wherein the ferromagnetic nanoparticles are selected from the group consisting of a ferrite, a combination of an iron oxide and a ferromagnetic metal oxide, and combinations thereof; and
exposing the build material to electromagnetic radiation having a frequency ranging from about 5 kHz to about 300 GHz, thereby sintering the portion of the build material in contact with the first liquid functional material;
wherein the build material is a ceramic build material, and wherein the ferromagnetic nanoparticles consist of a mixture of Fe 2 O 3 , CoO, and Mn 2 O 3 nanoparticles.

Assignees

• Hewlett Packard Development Co

Inventors

• Abbott Jr James Elmer
• Kasperchik Vladek
• Champion David A

Classifications

• B33Y70/10

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

• B29C2035/0283

  Thermal pretreatment of the plastics material · CPC title

• C04B2235/667

  Sintering using wave energy, e.g. microwave sintering · CPC title

• B29C35/0805

  using electromagnetic radiation · CPC title

• C04B35/2666

  Other ferrites containing nickel, copper or cobalt · CPC title