Controlling green body object deformation

Patent metadata

Field	Value
Publication number	US-12138685-B2
Application number	US-201917052597-A
Country	US
Kind code	B2
Filing date	Mar 18, 2019
Priority date	Mar 18, 2019
Publication date	Nov 12, 2024
Grant date	Nov 12, 2024

Abstract

A shaping composition for controlling deformation of a green body object during heat fusing can include a liquid vehicle present at from 10 wt % to about 80 wt %, based on a total weight of the shape retaining composition, and a metal particulate mixture present at from about 20 wt % to about 90 wt % based on a total weight of the shaping composition. The metal particulate mixture can include aluminum-containing particulates and secondary metal-containing particulates. The metal particulate mixture can have an aluminum elemental content to secondary metal elemental content atomic ratio of about 10:1 to about 1:2.

First claim

What is claimed is:

1. A three-dimensional printing kit, comprising:
a particulate build material comprising from about 80 wt % to 100 wt % metal build particles having a D50 particle size distribution value ranging from about 50 μm to about 150 μm;
a binding agent contained separately from the particulate build material and including a build binder to apply to particulate build material layers to form a green body object; and
a shaping composition to apply to a surface of the green body object to ameliorate deformation within an intermediate temperature range where the build binder is not effective at retaining the green body object shape prior to the metal build particles becoming heat-fused, the shaping composition including:
a water-based liquid vehicle present at from 20 wt % to about 30 wt %, based on a total weight of the shape composition;
from about 65 wt % to about 75 wt %, based on the total weight of the shaping composition, of a metal particulate mixture including aluminum-containing particulates and iron-containing particulates independently having a D50 particle size ranging from about 5 μm to about 100 μm; and
from about 5 wt % to about 15 wt % of a shaping binder;
wherein a viscosity of the shaping composition ranges from about 50 cps to about 5000 cps.

2. The three-dimensional printing kit of claim 1 , wherein an atomic ratio of aluminum-to-iron present in the metal particulate mixture ranges from about 10:1 to about 1:2.

3. The three-dimensional printing kit of claim 1 , wherein the metal build particles are copper-containing metal particles including from 50 wt % to 100 wt % of elemental copper.

4. The three-dimensional printing kit of claim 1 , wherein the shaping binder is a reducible-metal compound shaping binder.

5. The three-dimensional printing kit of claim 1 , wherein the build binder is latex particles having a weight average molecular weight ranging from about 10,000 Mw to about 500,000 Mw.

6. The three-dimensional printing kit of claim 1 , wherein the aluminum-containing particulates and secondary metal-containing particulates independently have a D50 particle size ranging from about 50 μm to about 100 μm.

7. The three-dimensional printing kit of claim 1 , wherein the shaping composition consists of:
about 75 wt % of the metal particulate mixture;
about 5 wt % of the shaping binder; and
about 20 wt % of the water-based liquid vehicle, wherein the water-based liquid vehicle consists of water, an organic co-solvent, and a combination thereof.

8. The three-dimensional printing kit of claim 1 , wherein:
the metal build particles are copper; and
the build binder is copper nitrate or copper chloride.

9. The three-dimensional printing kit of claim 1 , wherein the shaping composition consists of:
about 65 wt % of the metal particulate mixture;
the shaping binder consisting of about 5 wt % copper nitrate and about 10 wt % aluminum oxide; and
about 20 wt % of the water-based liquid vehicle.

10. A method of controlling green body object deformation comprising:
forming the green body object by:
iteratively applying individual build material layers of a particulate build material comprising from about 80 wt % to 100 wt % metal build particles having a D50 particle size distribution value ranging from about 50 μm to about 150 μm; and
based on a 3D object model, selectively applying a binding agent, including a build binder, to individual build material layers to define individually patterned layers that are built up and bound together with the build binder to form the green body object, the binding agent being contained separately from the particulate build material;

applying a coating of a shaping composition to a surface of the green body object at a surface location to ameliorate deformation within an intermediate temperature range where the build binder is not effective at retaining the green body object shape prior to the metal build particles becoming heat-fused, wherein the shaping composition includes:
a water-based liquid vehicle present at from 20 wt % to about 30 wt % based on a total weight of the shape composition;
from about 65 wt % to about 75 wt %, based on the total weight of the shaping composition, of a metal particulate mixture including aluminum-containing particulates and secondary metal-containing particulates independently having a D50 particle size ranging from about 5 μm to about 100 μm, wherein the secondary metal-containing particulates are iron-containing particulates; and
from about 5 wt % to about 15 wt % of a shaping binder;
wherein a viscosity of the shaping composition ranges from about 50 cps to about 5000 cps;

ramping-up temperature applied to the green body object though an intermediate temperature range where: multiple types of metal particulates of the shaping composition interact with one another, metal particulates of the shaping composition interact with metal build particles of the green body object, or both, wherein the shaping composition counteracts temperature induced deformation of the green body object while the green body object is within the intermediate temperature range; and
fusing the green body object at a fusing temperature to form a fused metal object.

Assignees

• Hewlett Packard Development Co

Inventors

• Jangam John Samuel Dilip
• Anthony Thomas
• Zhao Lihua

Classifications

• B22F2304/10

  Micron size particles, i.e. above 1 micrometer up to 500 micrometer · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B22F10/14 Primary

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

• B22F1/09

  Mixtures of metallic powders · CPC title