Three-dimensional printing

Patent metadata

Field	Value
Publication number	US-11890809-B2
Application number	US-201917298852-A
Country	US
Kind code	B2
Filing date	Jul 17, 2019
Priority date	Jul 17, 2019
Publication date	Feb 6, 2024
Grant date	Feb 6, 2024

Abstract

A 3D printing kit can include a powder bed material comprising from about 80 wt % to 100 wt % polymer particles, a fusing agent to selectively apply to the powder bed material, and a hardener to selectively apply to the powder bed material. The polymeric particles can include a polyalkylene backbone with both ethylene and propylene polymerized monomeric units with from 2 mol % to 15 mol % of the polymerized monomeric units include a grafted side chain having an epoxide moiety. The fusing agent can include water and a radiation absorber that absorbs electromagnetic energy and converts the electromagnetic energy to heat. The hardener can be present in the fusing agent or can be included in a hardening agent that is separate from the fusing agent.

First claim

What is claimed is:

1. A 3D printing kit comprising:
a powder bed material comprising from about 80 wt % to 100 wt % polymer particles, the polymeric particles including a polyalkylene backbone with both ethylene and propylene polymerized monomeric units, wherein from 2 mol % to 15 mol % of the polymerized monomeric units include a grafted side chain having an epoxide moiety;
a fusing agent to selectively apply to the powder bed material, wherein the fusing agent comprises water and a radiation absorber that absorbs electromagnetic energy and converts the electromagnetic energy to heat; and
a hardener to selectively apply to the powder bed material, wherein the hardener is present in the fusing agent or is included in a hardening agent that is separate from the fusing agent.

2. The 3D printing kit of claim 1 , wherein the hardener is included in the fusing agent.

3. The 3D printing kit of claim 1 , wherein the hardening agent is present and the hardener is included in the hardening agent.

4. The 3D printing kit of claim 1 , wherein the polymeric particles have a weight average molecular weight from about 10,000 Mw to about 75,000 Mw and an average particle size from about 10 μm to about 150 μm.

5. The 3D printing kit of claim 1 , wherein the polymeric particles have a weight average molecular weight from about 20,000 Mw to about 50,000 Mw and an average particle size from about 20 μm to about 75 μm.

6. The 3D printing kit of claim 1 , wherein the radiation absorber is a metal dithiolene complex, carbon black, a near-infrared absorbing dye, a near-infrared absorbing pigment, metal nanoparticles, a conjugated polymer, or a combination thereof.

7. The 3D printing kit of claim 1 , wherein the hardening agent includes water and from about 5 wt % to 50 wt % of the hardener which is selected from an amine hardener, a thiol hardener, an anhydride hardener, an isocyanate hardener, or a combination thereof.

8. The 3D printing kit of claim 1 , further comprising a detailing agent comprising a detailing compound, wherein the detailing compound reduces the temperature of powder bed material onto which the detailing agent is applied.

9. The powder bed material of claim 1 , wherein from 3 mol % to 10 mol % of the polymerized monomeric units includes the grafted side chain of the epoxide moiety.

10. The powder bed material of claim 1 , wherein the polymeric particles are a reaction product of a polypropylene-b-polyethylene random copolymer and a glycidyl (meth)acrylate.

11. A method of 3D printing comprising:
iteratively applying individual build material layers of polymer particles to a powder bed, the polymeric particles including a polyalkylene backbone with both ethylene and propylene polymerized monomeric units, wherein from 2 mol % to 15 mol % of the polymerized monomeric units include a grafted side chain having an epoxide moiety;
based on a 3D object model, selectively jetting a fusing agent onto the individual build material layers, wherein the fusing agent comprises water and a radiation absorber that absorbs electromagnetic energy and converts the electromagnetic energy to heat;
based on the 3D object model, selectively jetting a hardener onto the individual build material layers to cause epoxide moieties to open and become crosslinked, wherein the hardener is present in the fusing agent or separately jetted onto the individual build material layers as part of a separate hardening agent; and
exposing the powder bed to electromagnetic energy to selectively fuse the polymer particles in contact with the radiation absorber at individual build material layers to form a 3D printed article.

12. The method of claim 11 , wherein the 3D printed article formed is both physically fused by thermoplastic melting of particles and is chemically crosslinked at opened epoxy groups.

13. The method of claim 11 , wherein the 3D printed article formed has a Young's Modulus of 3,000 MPa or more.

14. A 3D printing system comprising:
a powder bed material comprising from about 80 wt % to 100 wt % polymer particles, the polymeric particles including a polyalkylene backbone with both ethylene and propylene polymerized monomeric units, wherein from 2 mol % to 15 mol % of the polymerized monomeric units include a grafted side chain having an epoxide moiety;
a fusing agent to selectively apply to the powder bed material, wherein the fusing agent comprises water and a radiation absorber that absorbs electromagnetic energy and converts the electromagnetic energy to heat;
a hardener to selectively apply to the powder bed material, wherein the hardener is present in the fusing agent or is included in a hardening agent that is separate from the fusing agent; and
a radiant energy source positioned to expose a layer of powder bed material to the electromagnetic energy to selectively fuse the polymer particles in contact with the radiation absorber and thereby form a 3D printed article that thermally fused and chemically crosslinked.

15. The 3D printing system of claim 14 , wherein the hardening agent is present and the hardener is included in the hardening agent.

Assignees

• Hewlett Packard Development Co

Inventors

• Wycoff Kyle
• Olubummo Adekunle
• Querol Esparch Maria Del Carmen
• Herschke Laurent
• Zhao Lihua

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

• B33Y10/00 Primary

  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

• C09D11/037

  characterised by the pigment · CPC title