Three-dimensional printing

Patent metadata

Field	Value
Publication number	US-11833751-B2
Application number	US-201917294445-A
Country	US
Kind code	B2
Filing date	Jun 10, 2019
Priority date	Jun 10, 2019
Publication date	Dec 5, 2023
Grant date	Dec 5, 2023

Abstract

A materials kit for 3D printing can include a powder bed material including from about 60 wt % to 100 wt % composite fibers having an average aspect ratio from about 3:1 to about 30:1 and a fusing agent including an energy absorber to absorb electromagnetic radiation to produce heat. The composite fibers can include glass fibers coated with an encapsulating polymer, wherein the glass fibers can be included at from about 5 wt % to about 40 wt % based on the total weight of the powder bed material.

First claim

What is claimed is:

1. A materials kit for 3D printing comprising:
a powder bed material including from about 60 wt % to 100 wt % composite fibers having an average aspect ratio from about 3:1 to about 30:1, the composite fibers including glass fibers at from about 5 wt % to about 40 wt % based on the total weight of the powder bed material, wherein the glass fibers include at least one of glass fibers coated with an encapsulating polymer, uncoated glass fibers, or a combination thereof; and
a fusing agent comprising an energy absorber to absorb electromagnetic radiation to produce heat.

2. The materials kit of claim 1 , wherein the composite fibers have a bulk density from about 0.18 g/cc to about 0.6 g/cc.

3. The materials kit of claim 1 , wherein the composite fibers include from about 5 wt % to about 18 wt % high aspect ratio glass fibers having an aspect ratio from about 7:1 to about 90:1.

4. The materials kit of claim 1 , wherein the composite fibers include from about 10 wt % to about 40 wt % low aspect ratio glass fibers having an aspect ratio from about 1.3:1 to about 6.9:1 and a D50 particle size distribution, by volume, from about 70 μm to about 100 μm.

5. The materials kit of claim 1 , further comprising filler particles having an average aspect ratio of 1:1 to about 1.3:1 and a D50 particle size distribution, by volume, from about 5 μm to about 70 μm.

6. The materials kit of claim 1 , wherein the glass fibers include an organosilane coupling agent attached to a surface thereof.

7. The materials kit of claim 1 , wherein the energy absorber comprises a carbon black pigment, a near-infrared absorbing dye, a near-infrared absorbing pigment, a tungsten bronze, a molybdenum bronze, metal nanoparticles, a conjugated polymer, or a combination thereof.

8. The materials kit of claim 1 , wherein a portion of the about 5 wt % to about 40 wt % glass fibers are the uncoated glass fibers.

9. A method of making a 3D printed article, comprising:
iteratively applying individual build material layers of a powder bed material including from about 60 wt % to 100 wt % composite fibers having an average aspect ratio from about 3:1 to about 30:1, the composite fibers including glass fibers coated with an encapsulating polymer based on a total weight of the powder bed material, wherein the glass fibers are included at from about 5 wt % to about 40 wt % based on the total weight of the powder bed material;
based on a 3D object model, selectively jetting a fusing agent onto individual build material layers, where the fusing agent comprises an energy absorber; and
exposing the powder bed material to electromagnetic energy to selectively fuse the composite fibers in contact with the energy absorber at individual build material layers to form a 3D printed article.

10. The method of claim 9 , further comprising maintaining the 3D printed article at a temperature from about 140° C. to about 180° C. for a period from about 30 minutes to about 72 hours after formation of the 3D printed article.

11. The method of claim 9 , further comprising allowing the 3D printed article to cool immediately following formation of the 3D printed article.

12. The method of claim 9 , wherein the printed article has a tensile strength in the X-Y axis from about 25 MPa to about 65 MPa, a Young's modulus in the X-Y axis from about 1600 MPa to about 4500 MPa, and a strain at break in the X-Y axis from about 4% to about 50%.

13. A 3D printing system, comprising:
a powder bed material including from about 60 wt % to 100 wt % composite fibers having an average aspect ratio from about 3:1 to about 30:1, the composite fibers including glass fibers coated with an encapsulating polymer based on a total weight of the powder bed material, wherein the glass fibers are included at from about 5 wt % to about 40 wt % based on the total weight of the powder bed material;
a fusing agent to eject onto the powder bed material, wherein the fusing agent comprises an energy absorber capable of absorbing electromagnetic radiation to produce heat; and
a fusing electromagnetic radiation source to expose the powder bed material to electromagnetic radiation to fuse composite fibers that have been contacted by the fusing agent via ejection, but which does not fuse the composite fibers not contacted by the fusing agent.

14. The system of claim 13 , wherein the encapsulating polymer includes polyamide-12, polyamide-11, polyamide-6-13, polyamide-6, polypropylene, thermoplastic polyamide, thermoplastic polyurethane, or a combination thereof.

15. The system of claim 13 , wherein the composite fibers have a melt flow index value from about 10 to about 80 at a temperature of 235° C. and a load of 5 kg.

Assignees

• Hewlett Packard Development Co

Inventors

• Tandy Jesiska
• Kozmiski Stanley J
• Yemane Alay

Classifications

• 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

• B29C64/264

  Arrangements for irradiation · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title