Green body including a metal nanoparticle binder

Patent metadata

Field	Value
Publication number	US-12005641-B2
Application number	US-202217857362-A
Country	US
Kind code	B2
Filing date	Jul 5, 2022
Priority date	Jul 31, 2017
Publication date	Jun 11, 2024
Grant date	Jun 11, 2024

Abstract

According to an example, a green body may include from about 1 wt. % to about 20 wt. % of a metal nanoparticle binder and a build material powder, wherein the metal nanoparticle binder is selectively located within an area of the green body to impart a strength greater than about 3 MPa.

First claim

What is claimed is:

1. A method, comprising:
spreading a layer of a metal or metal alloy build material powder;
selectively depositing from about 1 wt. % to about 20 wt. % of a metal nanoparticle binder onto the layer of the metal or metal alloy build material powder; and
applying energy to form a green body from the layer of the metal or metal alloy build material powder and the metal nanoparticle binder deposited on the layer of the metal or metal alloy build material powder,
wherein the metal nanoparticle binder is selectively located within a first area of the green body to impart a strength greater than about 3 MPa in the first area.

2. The method of claim 1 , further comprising selectively applying a polymer binder to the layer of the metal or metal alloy build material powder.

3. The method of claim 1 , wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a bridge.

4. The method of claim 1 , wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a cantilever.

5. The method of claim 1 , wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a wall with thickness at or below a threshold.

6. The method of claim 1 , wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including an exterior corner or edge.

7. The method of claim 1 , wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a middle section of a high aspect ratio part.

8. The method of claim 1 , wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a junction between adjacent parts of the green body.

9. A method, comprising:
spreading a layer of a build material powder;
selectively depositing a first agent including from about 1 wt. % to about 20 wt. % of a metal nanoparticle binder onto the layer of the build material powder;
selectively depositing a second agent including a polymer binder onto the layer of the build material powder, wherein the polymer binder is selected from the group consisting of polypropylene, polyethylene, low density polyethylene, high density polyethylene, polyethylene oxide, polyethylene glycol, polystyrene, polyphenyl ether, polyamide 11, polyamide 12, polymethyl pentene, polyoxymethylene, polyethylene terephthalate, polybutylene terephthalate, polyvinylidene fluoride, polytetrafluoroethylene, perfluoroalkoxy alkane, polyphenylene sulfide, and polyether ether ketone; and
applying energy to form a green body from the layer of build material powder and the first and second agents deposited on the layer of the build material powder,
wherein the first agent including the metal nanoparticle binder is selectively located within a first area of the green body to impart a strength greater than about 3 MPa in the first area.

10. The method of claim 1 , wherein the metal nanoparticle binder is selected from the group consisting of AlN, SiC, Si 3 N 4 , WC, Al 2 O 3 , Al(OH) 3 , Fe 2 O 3 , Fe 3 O 4 , MgO, SiO 2 , TiO 2 , Y 2 O 3 , ZnO, ZrO 2 , BaCO 3 , In 2 O 3 , SnO 2 , carbon, magnesium, manganese, aluminum, iron, titanium, niobium, tungsten, chromium, tantalum, cobalt, nickel, vanadium, zirconium, molybdenum, palladium, platinum, copper, silver, gold, cadmium, zinc, and combinations thereof.

11. The method of claim 1 , wherein the metal nanoparticle binder is present in an amount ranging from about 1 wt. % to about 15 wt. %.

12. The method of claim 1 , wherein the first area of the green body has a predicted internal stress that exceeds about 1 MPa based upon analysis of the green body.

13. The method of claim 1 , wherein the metal present in the metal nanoparticle binder is the same as a metal in the metal material powder.

14. The method of claim 2 , wherein the selectively depositing includes selectively depositing an agent including the metal nanoparticle binder and the polymer binder.

15. The method of claim 1 , wherein the metal nanoparticle binder is present in an amount ranging from about 1 wt. % to about 5 wt. %.

Assignees

• Hewlett Packard Development Co

Inventors

• Erickson Kristopher J
• Anthony Thomas C

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B22F1/054

  Nanosized particles · CPC title

• C04B2235/667

  Sintering using wave energy, e.g. microwave sintering · CPC title

• C04B2235/6026

  Computer aided shaping, e.g. rapid prototyping · CPC title

• C04B2235/5454

  nanometer sized, i.e. below 100 nm · CPC title