Three-dimensional printing with supportive coating agents

Patent metadata

Field	Value
Publication number	US-12330213-B2
Application number	US-201917641253-A
Country	US
Kind code	B2
Filing date	Nov 8, 2019
Priority date	Nov 8, 2019
Publication date	Jun 17, 2025
Grant date	Jun 17, 2025

Abstract

A three-dimensional printing kit can include a particulate build material, a binding agent, and a supportive coating agent. The particulate build material can include from about 80 wt % to about 100 wt % metal particles based on the total weight of the particulate build material. The binding agent can include binder particles dispersed in a binder liquid vehicle. The supportive coating agent can include ceramic particles having a negative coefficient of thermal expansion, a gelling compound, and a supportive coating liquid vehicle.

First claim

What is claimed is:

1. A three-dimensional printing kit, comprising:
a particulate build material including from about 80 wt % to about 100 wt % of metal particles based on the total weight of the particulate build material;
a binding agent including binder particles dispersed in a binder liquid vehicle; and
a supportive coating agent including:
ceramic particles having a negative coefficient of thermal expansion;
a gelling compound selected from the group consisting of sodium metasilicate, potassium metasilicate, sodium orthosilicate, sodium pyrosilicate, organo orthosilicate, tetraethyl orthosilicate, and a combination thereof; and
a supportive coating liquid vehicle,
wherein a weight ratio of the ceramic particles to the gelling compound ranges from about 1:1 to about 1:9.

2. The three-dimensional printing kit of claim 1 , wherein the metal particles are selected from the group consisting of aluminum particles, titanium particles, copper particles, cobalt particles, chromium particles, nickel particles, vanadium particles, tungsten particles, tungsten carbide particles, tantalum particles, molybdenum particles, magnesium particles, gold particles, silver particles, stainless steel particles, steel particles, and an admixture thereof.

3. The three-dimensional printing kit of claim 1 , wherein the metal particles have a D50 particle size distribution value of from about 2 μm to about 150 μm.

4. The three-dimensional printing kit of claim 1 , wherein the ceramic particles are selected from the group consisting of zirconium tungstate particles, titanium carbide particles, silicon nitride particles, silicon carbide particles, boron nitride particles, kaolin silicate particles, eucryptite particles, cordierite particles, cyanide particles, calcium cyanamide particles, and a combination thereof.

5. The three-dimensional printing kit of claim 1 , wherein the ceramic particles are zirconium tungstate particles and the gelling compound is the sodium metasilicate, and wherein the zirconium tungstate particles are dispersed in a gel formed from the sodium metasilicate and the supportive coating liquid vehicle.

6. The three-dimensional printing kit of claim 1 , wherein the weight ratio of the ceramic particles to the gelling compound ranges from about 1:2 to about 1:7.

7. The three-dimensional printing kit of claim 1 , wherein the gelling compound is selected from the group consisting of potassium metasilicate, sodium orthosilicate, sodium pyrosilicate, organo orthosilicate, and a combination thereof.

8. A three-dimensional printing system utilizing the three-dimensional printing kit of claim 1 , the system comprising:
a binding agent applicator fluidly coupled or coupleable to the binding agent to iteratively apply the binding agent to the particulate build material to form individually patterned object layers of a green body object; and
a heat source to heat the green body object with the supportive coating agent thereon to a coating-hardening temperature to harden the supportive coating agent and form a supportive coating on the green body object.

9. The three-dimensional printing system of claim 8 , wherein:
the system further comprises a sintering oven to receive and heat the green body object with the supportive coating thereon to a metal particle-fusing temperature to form a heat-fused three-dimensional object; or
the heat source is a sintering oven to heat the green body object with the supportive coating thereon to a metal particle-fusing temperature that is higher than the coating-hardening temperature to thereby heat the green body object sufficient to form a heat-fused three-dimensional object.

10. A method of three-dimensional printing, the method comprising:
iteratively applying individual build material layers of a particulate build material which includes from about 80 wt % to about 100 wt % of metal particles based on the total weight of the particulate build material;
based on a three-dimensional object model, iteratively applying a binding agent to individual build material layers to define individually patterned object layers that become adhered to one another to form a green body object, the binding agent including binder particles dispersed in a binder liquid vehicle;
coating the green body object with a supportive coating agent, the supportive coating agent including:
ceramic particles having a negative coefficient of thermal expansion;
a gelling compound selected from the group consisting of sodium metasilicate, potassium metasilicate, sodium orthosilicate, sodium pyrosilicate, organo orthosilicate, tetraethyl orthosilicate, and a combination thereof; and
a supportive coating liquid vehicle,
wherein a weight ratio of the ceramic particles to the gelling compound ranges from about 1:1 to about 1:9;

heating the green body object to a coating-hardening temperature to harden the supportive coating agent thereon and form a supportive coating on the green body object; and
heating the green body object to a metal particle-fusing temperature that is higher than the coating-hardening temperature to form a heat-fused three-dimensional object.

11. The method of claim 10 , further comprising removing the supportive coating from the heat-fused three-dimensional object.

12. The method of claim 11 , wherein the removing of the supportive coating includes sand-blasting, water-blasting, dry-ice blasting, ice-blasting, vacuuming, ultra-sonicating, brushing, or a combination thereof.

13. The method of claim 10 , wherein the method further includes preparing the supportive coating agent by dispersing the ceramic particles in a gel of the supportive coating liquid vehicle and the gelling compound.

14. The method of claim 10 , wherein the coating of the green body object includes applying the coating at a thickness ranging from about 0.2 mm to about 2 mm.

15. The method of claim 10 , wherein the heating of the green body object to the coating-hardening temperature to harden the supportive coating agent is at a temperature from about 100° C. to about 200° C., and wherein the heating of the green body object to the metal particle-fusing temperature that is higher than the coating-hardening temperature is at a temperature from about 10° C. to about 1,050° C. below a melting temperature of the metal particles of the particulate build material for a time period of from about a half hour to about twenty-four hours.

Assignees

• Peridot Print Llc

Inventors

• Pon Ben
• Jangam John Samuel Dilip
• Wycoff Kyle
• Zhao Lihua

Classifications

• B22F1/107

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

• B22F2304/10

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

• B22F2302/45

  Others, including non-metals · CPC title

• B22F2301/205

  Titanium, zirconium or hafnium · 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