Method for additive manufacturing of 3D-printed articles

Patent metadata

Field	Value
Publication number	US-11111184-B2
Application number	US-201615780643-A
Country	US
Kind code	B2
Filing date	Dec 2, 2016
Priority date	Dec 4, 2015
Publication date	Sep 7, 2021
Grant date	Sep 7, 2021

Abstract

The present invention provides a method of additive manufacturing a 3D-printed article, comprising: (a) printing and depositing one or more layers of a slurry by using a 3D printer, wherein the slurry comprises a ceramic powder composition; (b) further injecting an oil around the one or more layers of slurry, wherein the height of the injected oil is lower than the height of the slurry; (c) repeating steps (a) and (b) until a main body with desired geometric shape is obtained; and (d) sintering the main body by heating to obtain the 3D-printed article wherein the temperature of a printing carrier of the 3D printer is from 30 to 80° C.

First claim

What is claimed is:

1. A method for additive manufacturing a 3D-printed article, comprising:
(a) printing and depositing one or more layers of a slurry by using a 3D printer to obtain a printed ceramic object, wherein the slurry comprises a ceramic powder composition;
(b) covering outer periphery of the printed ceramic object with an oil; and
(c) sintering the oil-covered printed ceramic object from step (b) by heating to obtain the 3D-printed article wherein the temperature of a printing carrier of the 3D printer is from 30 to 80° C.

2. The method of claim 1 , wherein the ceramic powder comprises hydroxylapatite, tricalcium phosphate, high density alumina, zirconia, bioglass, carbide ceramic materials, nitride ceramic materials, aluminum silicate, boride ceramic materials or silicide ceramic materials.

3. The method of claim 1 , wherein the oil comprises polyglycol, silicone oil, fluorinated oil, phosphoric ester, polyether, paraffin, dodecyl alcohol, olive oil, soybean oil, hydrocarbon mineral oil, liquid paraffin, or synthetic hydrocarbon.

4. The method of claim 1 , wherein the viscosity of the slurry ranges from 100 to 900 cP.

5. The method of claim 1 , wherein the size of a nozzle of the 3D printer ranges from 19 to 30G.

6. The method of claim 1 , wherein the printing speed of the 3D printer ranges from 0.1 to 5 cm/s.

7. The method of claim 1 , wherein the slurry in step (a) comprises a ceramic powder composition and a hydrogel, and the slurry is prepared by following steps:
(1) synthesizing poly(N-isopropylacrylamide) (p(NiPAAm)) or poly(N-isopropylacrylamide-co-methacrylic acid) (p(NiPAAm-MAA));
(2) mixing a dispersant with hydroxylapatite;
(3) mixing the p(NiPAAm) or the p(NiPAAm-MAA) of step (a) with water to obtain a hydrogel solution;
(4) mixing the hydrogel solution of step (c) with product of step (b) to produce a mixture; and
(5) stirring the mixture of step (4) to produce the slurry.

8. The method of claim 7 , which further comprise adding polymer particles to the mixture of step (4) prior to step (5).

9. The method of claim 7 , wherein the hydroxylapatite and the dispersant of step (2) are mixed in a weight ratio ranging from 25:1 to 25:5.

10. The method of claim 7 , wherein the dispersant of step (2) is polyacrylic acid (PAA), polymethacrylic acid (PMA), or polyvinyl alcohol (PVA).

11. The method of claim 7 , wherein the p(NiPAAm-MAA) and the water of step (3) are mixed in a volume ratio ranging from 1:10 to 2:1.

12. The method of claim 7 , which further comprises adding a photocuring initiator to the hydrogel solution of step (3) to allow the slurry to be photocured and molded after being irradiated by UV light.

13. The method of claim 12 , wherein the photocuring initiator is a radical type photocuring initiator or a cationic type photocuring initiator.

14. The method of claim 13 , wherein the radical type photocuring initiator comprises acrylic acid or unsaturated polyester, the cationic photocuring initiator comprises an epoxy compound, oxetane or vinyl ether.

Assignees

• Univ Kaohsiung Medical

Inventors

• Wang Chih-Kuang
• Ho Mei-Ling
• Pan Li-Cheng
• Fu Yin-Chih
• Chen Chung-Hwan
• Chang Je-Ken

Classifications

• B22F10/12

  by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP] · CPC title

• B22F10/18

  by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF] · CPC title

• B22F12/53

  Nozzles · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• B33Y70/10

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