Three-dimensional printing

Patent metadata

Field	Value
Publication number	US-11958110-B2
Application number	US-201817047513-A
Country	US
Kind code	B2
Filing date	Oct 29, 2018
Priority date	Oct 29, 2018
Publication date	Apr 16, 2024
Grant date	Apr 16, 2024

Abstract

In an example of a method for three-dimensional printing, a first amount of a binding agent is selectively applied, based on a 3D object model, to individual build material layers of a particulate build material including metal particles to forming an intermediate structure. The binding agent and/or a void-formation agent is selectively applied, based on the 3D object model, to at least one interior layer of the individual build material layers so that a total amount of the binding agent, the void-formation agent, or both the binding agent and the void-formation agent in the at least one of the individual build material layers is greater than the first amount. This patterns an area that is to contain voids. The intermediate structure is heated to form a 3D structure including a void-containing breakable connection.

First claim

What is claimed is:

1. A method for three-dimensional printing, comprising:
based on a 3D object model, selectively applying a first amount of a binding agent to individual build material layers of a particulate build material, thereby forming an intermediate structure, wherein the particulate build material includes metal particles;
based on the 3D object model, selectively applying the binding agent to at least one interior layer of the individual build material layers so that a second amount of the binding agent in the at least one interior layer of the individual build material layers is greater than the first amount, thereby patterning an area of the intermediate structure that is to contain voids; and
heating the intermediate structure to form a 3D structure i) including a 3D object at areas patterned with the first amount of the binder agent and ii) including a void-containing breakable connection at the area patterned with the binding agent in the second amount greater than the first amount.

2. The method as defined in claim 1 wherein:
each of the individual build material layers has a thickness ranging from about 30 μm to about 120 μm;
the first amount ranges from about 0.12 grams per square meter (gsm) per 1 μm of build material layer thickness to about 0.26 gsm per 1 μm of build material layer thickness; and
the second amount ranges from about 0.3 gsm per 1 μm of build material layer thickness to about 0.6 gsm per 1 μm of build material layer thickness.

3. The method as defined in claim 1 wherein:
the intermediate structure includes a build material support structure and a patterned intermediate part; and
the at least one of the individual build material layers having the second amount of the binding agent therein defines a patterned breakable connection between the build material support structure and the patterned intermediate part.

4. The method as defined in claim 3 wherein the heating forms the 3D object from the patterned intermediate part, a 3D support structure from the build material support structure, and the void-containing breakable connection from the patterned breakable connection.

5. The method as defined in claim 4 , further comprising removing the 3D support structure from the 3D object by breaking the void-containing breakable connection.

6. The method as defined in claim 1 wherein the void-containing breakable connection includes the voids, and wherein an average diameter of the voids is equal to or greater than a thickness of each individual build material layer.

7. The method as defined in claim 1 wherein the void-containing breakable connection includes sintered metal particles.

8. The method as defined in claim 1 wherein the binding agent includes a binder and an aqueous vehicle, and wherein the binder is selected from the group consisting of a latex, polyvinyl alcohol, polyvinylpyrrolidone, and combinations thereof.

9. The method as defined in claim 8 wherein the binding agent further includes a co-solvent, a surfactant, an antimicrobial agent, an anti-kogation agent, or combinations thereof.

10. The method as defined in claim 1 wherein each of the selectively applying steps is accomplished using a thermal inkjet printhead or a piezoelectric inkjet printhead.

11. The method as defined in claim 1 wherein the 3D object formed at the areas patterned with the first amount of the binder agent is free of voids.

12. A method for three-dimensional printing, comprising:
based on a 3D object model, selectively applying a first amount of a binding agent to individual build material layers of a particulate build material, thereby forming an intermediate structure, wherein the particulate build material includes metal particles;
based on the 3D object model, selectively applying both the binding agent and a void-formation agent to at least one interior layer of the individual build material layers so that a total amount of the binding agent and the void-formation agent in the at least one interior layer of the individual build material layers is greater than the first amount, thereby patterning an area of the intermediate structure that is to contain voids; and
heating the intermediate structure to form a 3D structure i) including a 3D object at areas patterned with the first amount of the binder agent and ii) including a void-containing breakable connection at the area patterned with both the binding agent and the void-formation agent in the total amount.

13. The method as defined in claim 12 wherein:
each of the individual build material layers has a thickness ranging from about 30 μm to about 120 μm;
the first amount ranges from about 0.12 grams per square meter (gsm) per 1 μm of build material layer thickness to about 0.26 gsm per 1 μm of build material layer thickness; and
the total amount ranges from about 0.3 gsm per 1 μm of build material layer thickness to about 0.6 gsm per 1 μm of build material layer thickness.

14. The method as defined in claim 12 wherein:
the intermediate structure includes a build material support structure and a patterned intermediate part; and
the at least one of the individual build material layers having the total amount of both the binding agent and the void-formation agent therein defines a patterned breakable connection between the build material support structure and the patterned intermediate part.

15. The method as defined in claim 14 wherein the heating forms the 3D object from the patterned intermediate part, a 3D support structure from the build material support structure, and the void-containing breakable connection from the patterned breakable connection, and wherein the method further comprises removing the 3D support structure from the 3D object by breaking the void-containing breakable connection.

16. The method as defined in claim 12 wherein the void-formation agent includes water.

17. The method as defined in claim 12 wherein the void-containing breakable connection includes the voids, and wherein an average diameter of the voids is equal to or greater than a thickness of each individual build material layer.

Assignees

• Hewlett Packard Development Co

Inventors

• Hower Jason C
• Shaarawi Mohammed S
• Kasperchik Vladek P
• Mckinnell James
• Wu Jennifer L

Classifications

• B22F10/14 Primary

  by jetting of binder onto a bed of metal powder · CPC title

• B22F1/107

  containing organic material comprising solvents, e.g. for slip casting · CPC title

• B22F10/47

  characterised by structural features · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title