Three-dimensional shaped article production method

Patent metadata

Field	Value
Publication number	US-11878460-B2
Application number	US-202218061727-A
Country	US
Kind code	B2
Filing date	Dec 5, 2022
Priority date	Jan 22, 2016
Publication date	Jan 23, 2024
Grant date	Jan 23, 2024

Abstract

A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.

First claim

What is claimed is:

1. A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers, comprising:
a first layer formation step of forming a first layer above a stage by supplying a first composition being a first paste-formed mixture comprising ceramic particles and a binder;
a second layer formation step of forming a second layer composed of one or more layers on the first layer by supplying a second composition being a second paste-formed mixture comprising metal particles and a binder, the metal particles have a sintering temperature lower than the sintering temperature of the ceramic particles;
a heating step of heating the first layer and the second layer at a temperature above a sintering temperature of the metal particles to sinter the metal particles, the temperature being below a sintering temperature of the ceramic particles.

2. The three-dimensional shaped article production method according to claim 1 , wherein the first layer is formed above a ceramic plate arranged above the stage.

3. The three-dimensional shaped article production method according to claim 1 , wherein the first paste-formed mixture and the second paste-formed mixture are supplied in form of a continuous body.

4. The three-dimensional shaped article production method according to claim 1 , wherein the heating step is carried out using a heating chamber.

5. The three-dimensional shaped article production method according to claim 1 , wherein the heating step is performed at a temperature, which is lower than the melting points of the metal particles and the ceramic particles.

6. The three-dimensional shaped article production method according to claim 1 , wherein a binding force between the ceramic particles by the binder contained in the first composition is smaller than a binding force between the metal particles by the binder contained in the second composition.

7. The three-dimensional shaped article production method according to claim 6 , wherein the amount of the binder contained in the first composition is smaller than the amount of the binder contained in the second composition.

8. The three-dimensional shaped article production method according to claim 1 , wherein the first layer is a layer separated from the second layer after the heating step.

9. The three-dimensional shaped article production method according to claim 8 , wherein before the first layer is separated from the second layer, a separation promotion step of promoting a separation of the first and second layer from the stage is performed.

10. The three-dimensional shaped article production method according to claim 9 , wherein the decomposition temperature of the binder contained in the first composition is lower than the decomposition temperature of the binder contained in the second composition, and the separation promotion step is a heating step of performing heating at a temperature higher than the decomposition temperature of the binder contained in the first composition and lower than the decomposition temperature of the binder contained in the second composition.

11. The three-dimensional shaped article production method according to claim 9 , wherein the stage is configured to be capable of transmitting an electromagnetic wave, and the separation promotion step is an electromagnetic wave irradiation step of irradiating the first composition with an electromagnetic wave through the stage.

12. The three-dimensional shaped article production method according to claim 11 , wherein a titania layer is formed on the stage.

13. The three-dimensional shaped article production method according to claim 1 , wherein the arithmetic average surface roughness Ra of the stage is 5 μm or less.

Assignees

• Seiko Epson Corp

Inventors

• Ishida Masaya
• Okamoto Eiji
• Wada Hiroshi
• Hirai Toshimitsu

Classifications

• B29C64/112 Primary

  using individual droplets, e.g. from jetting heads · CPC title

• B22F3/1017

  Multiple heating or additional steps (B22F3/101 takes precedence) · CPC title

• B22F3/1021

  Removal of binder or filler (removal of binder from ceramics C04B35/638) · CPC title

• B22F10/16

  by embedding the binder within the powder bed · CPC title

• B22F10/20

  Direct sintering or melting · CPC title