Three-dimensional printing kits

Patent metadata

Field	Value
Publication number	US-12296386-B2
Application number	US-201917296964-A
Country	US
Kind code	B2
Filing date	Aug 9, 2019
Priority date	Aug 9, 2019
Publication date	May 13, 2025
Grant date	May 13, 2025

Abstract

A three-dimensional printing kit can include a binding agent and a particulate build material. The binding agent can include a binder in an aqueous liquid vehicle. The particulate build material can include from about 80 wt % to 100 wt % metal particles that can have a D50 particle size from about 5 μm to about 200 μm. Individual metal particles can include an iron-containing core and can have an oxidation barrier formed thereon. The iron-containing core can include from about 90 wt % to 100 wt % iron. The oxidation barrier can have a stable average thickness from about 0.5% to about 10% of a D50 particle size of the metal particles.

First claim

What is claimed is:

1. A method of three-dimensional printing, comprising:
iteratively applying individual build material layers of a particulate build material onto a powder bed, the particulate, build material consisting of metal particles having a D50 particle size of from about 5 μm to about 200 μm, wherein individual metal particles consist of an iron-containing core having an oxidation barrier formed thereon, wherein the iron-containing core includes from about 90 wt % to 100 wt % of iron, and wherein the oxidation barrier has a thickness ranging from about 5 μm to about 20 μm; and
based on a 3D object model, iteratively and selectively applying a binding agent to individual build material layers to define individually patterned object layers that become adhered to one another to form a layered green body object.

2. The method of claim 1 , wherein the iron-containing core is elemental iron.

3. The method of claim 1 , wherein the D50 particle size of the metal particles ranges from about 10 μm to about 150 μm.

4. The method of claim 1 , wherein the oxidation barrier is a Fe 3 O 4 layer.

5. The method of claim 1 , wherein the oxidization barrier is structured to resist moisture from reaching the iron-containing core.

6. The method of claim 1 , wherein an oxygen content of the oxidization barrier does not increase by more than 1000 ppm when exposed to a relative humidity of 25% at a temperature of 200° C.

7. The method of claim 1 , further comprising steam treating the iron-containing core with a dry steam having from about 0.1 wt % to about 5 wt % moisture content to form the metal particles with the oxidization barrier thereon.

8. The method of claim 7 , wherein the dry steam is applied at a temperature of from about 300° C. to about 500° C. for a time period of from about 5 minutes to about 30 minutes.

9. The method of claim 1 , further comprising heating the layered green body object to a temperature of from about 600° C. to about 1,500° C. to fuse the metal particles together and form a fused three-dimensional object.

10. The method of claim 1 , wherein the iron-containing core is a low alloy steel including from about 90 wt % to about 99.7 wt % of iron, from about 0.25 wt % to about 2.1 wt % of carbon, and from 0 wt % to about 8 wt % of a second metal selected from the group consisting of aluminum, chromium, copper, manganese, molybdenum, niobium, nickel, silicon, titanium, vanadium, zirconium, and a combination thereof.

Assignees

• Peridot Print Llc

Inventors

• Suri Pavan

Classifications

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• B22F2304/10

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

• B22F2301/35

  Iron · 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

• B22F1/145

  Chemical treatment, e.g. passivation or decarburisation · CPC title