Three-dimensional printing

Patent metadata

Field	Value
Publication number	US-11583920-B2
Application number	US-201716077772-A
Country	US
Kind code	B2
Filing date	Oct 12, 2017
Priority date	Feb 24, 2017
Publication date	Feb 21, 2023
Grant date	Feb 21, 2023

Abstract

An example of a method, for three-dimensional (3D) printing, includes applying a build material and patterning at least a portion of the build material. The patterning includes selectively applying a wetting amount of a binder fluid on the at least the portion of the build material and subsequently selectively applying a remaining amount of the binder fluid on the at least the portion of the build material. An area density in grams per meter square meter (gsm) of the wetting amount ranges from about 2 times less to about 30 times less than area density in gsm of the remaining amount.

First claim

What is claimed is:

1. A method for three-dimensional (3D) printing, comprising:
applying a layer of build material particles comprising at least one of metallic build material particles, ceramic build material particles, metallic and polymeric build material particles, or ceramic and polymeric build material particles; and
patterning at least a portion of the build material layer by:
selectively applying a wetting amount of a binder fluid on said at least the portion of the build material layer; and
subsequently selectively applying a remaining amount of the binder fluid on said at least the portion of the build material layer having the wetting amount applied thereon;

wherein:
a thickness of the applied build material layer is 100 microns, and the remaining amount of the binder fluid is applied in an amount ranging from about 12 gsm to about 45 gsm; or
a thickness of the applied build material layer is 200 microns, and the remaining amount of the binder fluid is applied in an amount ranging from about 37 gsm to about 68 gsm; or
a thickness of the applied build material layer is 500 microns, and the remaining amount of the binder fluid is applied in an amount ranging from about 45 gsm to about 252 gsm;
and wherein an area density in grams per square meter (gsm) of the wetting amount ranges from about 2 times less to about 30 times less than an area density in gsm of the remaining amount;

repeating the applying of the build material layer and the patterning to form a 3D part.

2. The method as defined in claim 1 wherein:
the selectively applying of the wetting amount and the selectively applying of the remaining amount take place in separate print passes; and
the selectively applying of the remaining amount of the binder fluid is accomplished in multiple print passes.

3. The method as defined in claim 1 wherein:
the selectively applying of the wetting amount and the selectively applying of the remaining amount take place in a single print pass using separate inkjet printheads that are spatially separated from one another.

4. The method as defined in claim 1 , further comprising:
heating the 3D part.

5. The method as defined in claim 4 :
heating the 3D part to a thermal decomposition temperature of a binder included in the binder fluid; and
heating the 3D part to a sintering temperature to form a sintered 3D part.

6. The method as defined in claim 4 wherein prior to the heating of the 3D part, the method further comprises:
evaporating a liquid vehicle of the binder fluid to activate a binder of the binder fluid; or

allowing the 3D part to reach an activation temperature to activate a binder of the binder fluid.

7. The method as defined in claim 1 , further comprising:
exposing the build material layer, including the patterned portion, to radiation, to fuse the patterned portion.

8. The method as defined in claim 1 :
wherein the binder fluid includes:
a binder or an active material; and
a liquid vehicle, wherein the liquid vehicle comprises a surfactant; and wherein the binder fluid has a surface tension of less than or equal to about 40 dyn/cm.

9. The method as defined in claim 1 wherein the thickness of the applied build material layer is 100 μm.

10. The method as defined in claim 1 wherein the patterning is performed based on a 3D object model.

11. A method for three-dimensional (3D) printing, comprising:
applying a layer of metallic build material particles;
patterning at least a portion of the metallic build material layer based on a 3D object model, the patterning involving:
selectively applying a wetting amount of a binder fluid on said at least the portion of the metallic build material layer; and
subsequently selectively applying a remaining amount of the binder fluid on said at least the portion of the metallic build material layer having the wetting amount applied thereon; wherein:
a thickness of the applied metallic build material layer is 100 microns, and the remaining amount of the binder fluid is applied in an amount ranging from about 12 gsm to about 45 gsm; or
a thickness of the applied metallic build material layer is 200 microns, and the remaining amount of the binder fluid is applied in an amount ranging from about 37 gsm to about 68 gsm; or
a thickness of the applied metallic build material layer is 500 microns, and the remaining amount of the binder fluid is applied in an amount ranging from about 45 gsm to about 252 gsm;
and wherein an area density in grams per square meter (gsm) of the wetting amount ranges from about 2 times less to about 30 times less than an area density in gsm of the remaining amount;

repeating the applying of the metallic build material layer and the patterning to form a patterned 3D part; and
activating a binder of the binder fluid to form a cured 3D part.

12. The method as defined in claim 11 , further comprising:
heating the cured 3D part to a thermal decomposition temperature of the binder; and
heating to a sintering temperature to form a sintered 3D part.

13. A method for three-dimensional (3D) printing, comprising:
applying a layer of build material particles comprising at least one of metallic build material particles, ceramic build material particles, metallic and polymeric build material particles, or ceramic and polymeric build material particles; and
patterning at least a portion of the build material layer by:
selectively applying a wetting amount of a binder fluid on said at least the portion of the build material layer; and
subsequently selectively applying a remaining amount of the binder fluid on said at least the portion of the build material layer having the wetting amount applied thereon:
wherein a thickness of the applied build material layer is 100 microns, the wetting amount of the binder fluid is applied in an amount ranging from about 1.5 gsm to about 8.5 gsm, and the remaining amount of the binder fluid is applied in an amount ranging about 12 gsm to about 42 gsm;
and wherein an area density in grams per square meter (gsm) of the wetting amount ranges from about 2 times less to about 30 times less than an area density in gsm of the remaining amount;

repeating the applying of the build material layer and the patterning to form a 3D part.

14. The method as defined in claim 13 wherein:
the wetting amount is sufficient to wet said at least the portion of the build material layer and is insufficient to form a puddle on a surface of the build material layer within said at least the portion of the build material layer; and
the remaining amount is sufficient to at least partially fill interstitial spaces in said at least the portion of the build material layer without displacing the build material particles within said at least the portion of the build material layer.

15. The method as defined in claim 13 , further comprising:
heating the 3D part, wherein the heating of the 3D part includes:
heating the 3D part to a thermal decomposition temperature of a binder included in the binder fluid; and
heating the 3D part to a sintering temperature to form a sintered 3D part.

16. The method of claim 13 wherein the binder fluid includes:
a binder or an active material; and
a liquid vehicle, wherein the liquid vehicle comprises a surfactant;
and wherein the binder fluid has a surface tension of less than or equal to about dyn/cm.

17. A method for three-dimensional (3D) printing, comprising:
applying a layer of build material particles comprising at least one of metallic build material particles, ceramic build material part

Assignees

• Hewlett Packard Development Co

Inventors

• Kasperchik Vladek
• Shaarawi Mohammed S
• Mckinnell James

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B22F2201/04

  CO or CO2 · CPC title

• B22F2201/02

  Nitrogen · CPC title

• B22F2201/013

  Hydrogen · CPC title

• B22F12/63

  Rollers · CPC title