Method for producing three-dimensional shaped article

Patent metadata

Field	Value
Publication number	US-11534964-B2
Application number	US-201816204112-A
Country	US
Kind code	B2
Filing date	Nov 29, 2018
Priority date	Nov 30, 2017
Publication date	Dec 27, 2022
Grant date	Dec 27, 2022

Abstract

Provided is a method which includes a first layer formation step of forming a first layer by using a first composition that contains a constituent material powder, a first powder, and a binder of a three-dimensional shaped article; a second layer formation step of forming a second layer by using a second composition that contains a second powder and a binder; a degreasing step of a stack containing the first layer and the second layer; and a sintering step of the stack, a decomposition point of the first powder is higher than decomposition points of the binder of the first layer and the binder of the second layer, a decomposition point of the second powder is higher than the decomposition point of the first powder, and a sintering temperature of the constituent material powder is higher than the decomposition point of the second powder.

First claim

What is claimed is:

1. A method for producing a three-dimensional shaped article in which the three-dimensional shaped article is produced by stacking layers, the method comprising:
forming a first layer out of the layers by using a first composition that contains a constituent material powder, a first powder, and a binder which constitute the three-dimensional shaped article;
forming a second layer out of the layers by using a second composition that is different from the first composition and contains a second powder and a binder so that the second layer is in contact with the first layer;
removing at least a part of the first powder, the binder of the first layer, and the binder of the second layer by heating a stack containing the first layer and the second layer; and
sintering the constituent material powder by heating the stack containing the first layer and the second layer,
wherein the first powder and the second powder are both resin materials,
a decomposition point of the first powder is higher than decomposition points of the binder of the first layer and the binder of the second layer,
a decomposition point of the second powder is higher than the decomposition point of the first powder,
a sintering temperature of the constituent material powder is higher than the decomposition point of the second powder,
the first composition and the second composition are solids at room temperature,
in the forming of the first layer, the first layer is formed by heating the first composition that includes each of the constituent material powder, the first powder, and the binder to a fluid state and performing injection, and
in the forming of the second layer, the second layer is formed by heating the second composition that includes each of the second powder and the binder to a fluid state and performing injection.

2. A method for producing a three-dimensional shaped article in which the three-dimensional shaped article is produced by stacking layers, the method comprising:
forming a first layer out of the layers by using a first composition that contains a constituent material powder, a first powder, and a binder which constitute the three-dimensional shaped article;
forming a second layer out of the layers by using a second composition that is different from the composition and contains a second powder and a binder so that the second layer is in contact with the first layer;
removing at least a part of the first powder, the binder of the first layer, and the binder of the second layer by heating a stack containing the first layer and the second layer; and
sintering the constituent material powder by heating the stack containing the first layer and the second layer,
wherein the first powder is a resin material and the second powder includes particles that include carbon,
a decomposition point of the first powder is higher than decomposition points of the binder of the first layer and the binder of the second layer,
a sintering temperature of the constituent material powder is higher than the decomposition point of the second powder,
the first composition and the second composition are solids at room temperature,
in the forming of the first layer, the first layer is formed by heating the first composition that includes each of the constituent material powder, the first powder, and the binder to a fluid state and performing injection, and
in the forming of the second layer, the second layer is formed by heating the second composition that includes each of the second powder and the binder to a fluid state and performing injection.

3. The method for producing a three-dimensional shaped article according to claim 1 ,
wherein the stack containing the first layer and the second layer has a region where the first layer overlaps with the second layer.

4. The method of producing a three-dimensional shaped article according to claim 1 ,
wherein the constituent material powder is a metal or non-oxide ceramics, and the sintering is performed under a reducing atmosphere.

5. The method for producing a three-dimensional shaped article according to claim 1 ,
wherein the constituent material powder is oxide ceramics, and the sintering is performed under an oxidizing atmosphere.

6. The method for producing a three-dimensional shaped article according to claim 1 ,
wherein the first composition and the second composition are pastes containing a solvent,
in the forming of the first layer, the first layer is formed by ejecting the first composition, and
in the forming of the second layer, the second layer is formed by ejecting the second composition.

Assignees

• Seiko Epson Corp

Inventors

• Okamoto Eiji
• Tsunoya Akihiko

Classifications

• B22F12/53

  Nozzles · CPC title

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B29C64/336

  of two or more materials · CPC title

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B22F3/1007

  Atmosphere (B22F3/1021 takes precedence) · CPC title