Build material composition

Patent metadata

Field	Value
Publication number	US-12042860-B2
Application number	US-202318199945-A
Country	US
Kind code	B2
Filing date	May 20, 2023
Priority date	Mar 15, 2018
Publication date	Jul 23, 2024
Grant date	Jul 23, 2024

Abstract

An example of a method for making a build material composition for three-dimensional (3D) printing includes freezing a dispersion of flow additive nanoparticles in a liquid to form a frozen liquid containing the flow additive nanoparticles. The frozen liquid containing the flow additive nanoparticles is lyophilized to form flow additive agglomerates having a porous, fractal structure. The flow additive agglomerates are mixed with a host metal. The flow additive nanoparticles have an average flow additive particle size ranging from about 1 to about 3 orders of magnitude smaller than an average host metal particle size of the host metal.

First claim

What is claimed is:

1. A three-dimensional (3D) printing kit, comprising:
a host metal; and
flow additive agglomerates to be mixed with the host metal, the flow additive agglomerates having a porous, fractal structure and including flow additive primary particles that:
have an average flow additive primary particle size ranging from about 1 to about 3 orders of magnitude smaller than an average host metal particle size; and
are reducible to at least one elemental metal in a reducing environment at a reducing temperature that is less than or equal to a sintering temperature of the host metal, or are pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal.

2. The 3D printing kit as defined in claim 1 , further comprising a binder agent to be applied, via an inkjet printhead, to at least a portion of a layer of a build material composition formed from mixing the flow additive agglomerates with the host metal.

3. The 3D printing kit as defined in claim 1 wherein the flow additive agglomerates have an average flow additive agglomerate particle size ranging from about 100 nm to about 300 μm.

4. The 3D printing kit as defined in claim 1 wherein the flow additive agglomerates have meso-sized pores.

5. The 3D printing kit as defined in claim 1 wherein the flow additive agglomerates have a density ranging from about 0.1% to 20% of a bulk density of a material of the flow additive nanoparticles.

6. The 3D printing kit as defined in claim 1 wherein:
the host metal has an average particle size of less than 20 μm; and
the average flow additive primary particle size ranges from about 5 nm to about 200 nm.

7. The 3D printing kit as defined in claim 1 wherein the flow additive primary particles are selected from the group consisting of:
a metal containing compound that is reducible to at least one elemental metal in a reducing environment at a reducing temperature less than or equal to a sintering temperature of the host metal, wherein the at least one elemental metal is capable of being incorporated into a bulk metal phase of the host metal in a final metal object;
an organic material that is pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal; and
a crosslinked organic particle that is pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal.

8. The 3D printing kit as defined in claim 1 wherein the flow additive primary particles are selected from the group consisting of i) a metal containing compound selected from the group consisting of vanadium oxide, a chromium oxide, an iron oxide, a cobalt oxide, a nickel oxide, a copper oxide, and a mixed transition metal oxide including any combination of these oxides, ii) a non-crosslinked organic material that is pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal, and iii) a crosslinked organic particle that is pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal.

9. The 3D printing kit as defined in claim 1 wherein the flow additive primary particles are selected from the group consisting of vanadium oxide, a chromium oxide, an iron oxide, a cobalt oxide, a nickel oxide, a copper oxide, and a mixed transition metal oxide including any combination of these oxides.

10. The 3D printing kit as defined in claim 1 wherein the flow additive primary particles include a non-crosslinked organic material that is pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal.

11. The 3D printing kit as defined in claim 10 wherein the non-crosslinked organic material is a heteropolymer including a hydrophobic component that makes up from about 65% to about 99.9% by weight of the heteropolymer, and a hydrophilic component that makes up from about 0.1% to about 35% by weight of the heteropolymer.

12. The 3D printing kit as defined in claim 10 wherein the non-crosslinked organic material is produced by emulsion polymerization or co-polymerization.

13. The 3D printing kit as defined in claim 1 wherein the flow additive primary particles are crosslinked organic particles that are pyrolyzable at a pyrolysis temperature that is less than the sintering temperature of the host metal.

14. The 3D printing kit as defined in claim 13 wherein the crosslinked organic particles have crosslinked polymer chains, a glass transition temperature (T g ) of at least 90° C., and a primary particle size of 50 nm or less.

15. The 3D printing kit as defined in claim 13 wherein the crosslinked organic particles are produced by emulsion polymerization or co-polymerization.

Assignees

• Hewlett Packard Development Co

Inventors

• Kasperchik Vladek
• Shaarawi Mohammed S
• Mckinnell James
• Chen Tienteh

Classifications

• B22F10/10

  Formation of a green body · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F10/73 Primary

  of powder · CPC title

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• B22F1/102

  Metallic powder coated with organic material · CPC title