Utilization of magnetic particles to improve z-axis strength of 3D printed objects

Patent metadata

Field	Value
Publication number	US-11951683-B2
Application number	US-202217862215-A
Country	US
Kind code	B2
Filing date	Jul 11, 2022
Priority date	Mar 13, 2020
Publication date	Apr 9, 2024
Grant date	Apr 9, 2024

Abstract

A method for improving z-axis strength of a 3D printed object is disclosed. For example, the method includes printing a three-dimensional (3D) object with a polymer and magnetic particles, heating the 3D object to a temperature at approximately a melting temperature of the polymer, and applying a magnetic field to the 3D object to locally move the magnetic particles in the polymer to generate heat and fuse the polymer around the magnetic particles to improve a z-axis strength of the 3D object.

First claim

What is claimed is:

1. A method, comprising:
printing a three-dimensional (3D) object with a print material comprising a polymer and magnetic particles;
heating the 3D object to a temperature at approximately a melting temperature of the polymer; and
applying an oscillating magnetic field to the 3D object to rotate the magnetic particles back and forth in accordance with a pattern of oscillation in the polymer to create localized heat in various internal locations of the 3D object to fuse the polymer around the magnetic particles.

2. The method of claim 1 , wherein the printing comprises:
printing a layer of the 3D object with the polymer;
dispensing the magnetic particles on top of the layer; and
repeating the printing the layer and the dispensing until the 3D object is printed.

3. The method of claim 1 , further comprising:
testing a z-axis strength of the 3D object after the oscillating magnetic field is applied; and
repeating the printing, the heating, and the applying when the z-axis strength of the 3D object fails testing.

4. The method of claim 1 , wherein a strength of the oscillating magnetic field comprises approximately 1 oersted.

5. The method of claim 1 , wherein the oscillating magnetic field is oscillated at a range of approximately 10 hertz (Hz) to 500 megahertz (MHz).

6. The method of claim 5 , wherein the oscillating magnetic field is oscillated at a range of approximately 250 Hz to 100 MHz.

7. The method of claim 6 , wherein the oscillating magnetic field is oscillated at a range of approximately 500 Hz to 10 MHz.

8. The method of claim 1 , wherein the printing is performed by a selective laser sintering (SLS) printer.

9. The method of claim 8 , wherein the magnetic particles comprise 0.1-15 weight percent of the print material and have an average particle diameter of 1 nanometer to 5 microns.

10. The method of claim 1 , wherein the printing is performed using a fused deposition modeling (FDM) printer.

11. The method of claim 10 , wherein the magnetic particles comprise 1-10 weight percent of the print material and have an average particle diameter of 10 nanometers to 10 microns.

12. A non-transitory computer-readable medium storing a plurality of instructions, which when executed by a processor, cause the processor to perform operations, the operations comprising:
printing a three-dimensional (3D) object with a print material comprising a polymer and magnetic particles;
heating the 3D object to a temperature at approximately a melting temperature of the polymer; and
applying an oscillating magnetic field to the 3D object to rotate the magnetic particles back and forth in accordance with a pattern of oscillation in the polymer to create localized heat in various internal locations of the 3D object to fuse the polymer around the magnetic particles.

13. The non-transitory computer-readable medium of claim 12 , wherein the printing comprises:
printing a layer of the 3D object with the polymer;
dispensing the magnetic particles on top of the layer; and
repeating the printing the layer and the dispensing until the 3D object is printed.

14. The non-transitory computer-readable medium of claim 12 , further comprising:
testing a z-axis strength of the 3D object after the oscillating magnetic field is applied; and
repeating the printing, the heating, and the applying when the z-axis strength of the 3D object fails testing.

15. The non-transitory computer-readable medium of claim 12 , wherein a strength of the oscillating magnetic field comprises approximately 1 oersted.

16. The non-transitory computer-readable medium of claim 12 , wherein the oscillating magnetic field is oscillated at a range of approximately 10 hertz (Hz) to 500 megahertz (MHz).

17. The non-transitory computer-readable medium of claim 16 , wherein the oscillating magnetic field is oscillated at a range of approximately 250 Hz to 100 MHz.

18. The non-transitory computer-readable medium of claim 17 , wherein the oscillating magnetic field is oscillated at a range of approximately 500 Hz to 10 MHz.

19. The non-transitory computer-readable medium of claim 17 , wherein the printing is performed by a selective laser sintering printer or a fused deposition modeling printer.

20. A method, comprising:
printing a three-dimensional (3D) object with a print material comprising a polymer and magnetic particles, wherein the magnetic particles have an average particle diameter of 50 nanometers to 3 microns and comprise 3 to 10 weight percent of the print material;
heating the 3D object to a temperature at approximately a melting temperature of the polymer; and
applying an oscillating magnetic field to the 3D object to align the magnetic particles in the polymer and to rotate the magnetic particles back and forth in accordance with a pattern of oscillation to generate heat that melts regions between layers of the 3D object to fuse the polymer around the magnetic particles and to promote entanglement of polymer chains between the layers.

Assignees

• Xerox Corp

Inventors

• Lu Chunliang
• Wolfe Christopher
• Ianni John
• Mercandetti Mark
• Pawlak John
• Cheng Chieh-Min

Classifications

• B29C64/188 Primary

  involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00) · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29C64/153

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

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B29K2995/0008

  Magnetic or paramagnetic · CPC title