Ceramic support structure

Patent metadata

Field	Value
Publication number	US-2016023373-A1
Application number	US-201414776007-A
Country	US
Kind code	A1
Filing date	Mar 14, 2014
Priority date	Mar 14, 2013
Publication date	Jan 28, 2016
Grant date	—

Abstract

A pre-ceramic support structure for additive manufacturing, that upon thermal processing, is soluble in various solvents.

First claim

1 - 15 . (canceled)

16 . A feedstock material for use in an additive manufacturing system, the feedstock material comprising:
a pre-ceramic material in powder form; a thermoplastic binder; and wherein upon thermal processing of the feedstock, the pre-ceramic material is removable in a solvent.

17 . The feedstock material of claim 1 , wherein the thermoplastic binder is a polymeric matrix comprising one or more of polyolefins, polylactic acid polymers, and acrylonitrile butadiene styrene polymers or combinations thereof.

18 . The feedstock material of claim 1 , wherein the pre-ceramic material comprises calcium carbonate, sodium carbonate, sodium aluminate or combinations thereof.

19 . The feedstock of claim 1 , wherein the solvent comprises water, carbonated solutions, acidic solutions and combinations thereof.

20 . The feedstock material of claim 1 , and further comprising one or more of a fluxing materials, a polymer processing additive or combinations thereof.

21 . The feedstock material of claim 5 , wherein the fluxing material comprises glass frits having boron trioxide, silicon oxide, zirconium dioxide, lithium oxide, fluorine, titanium dioxide, and combinations thereof.

22 . The feedstock of claim 1 , wherein the feedstock material is a filament produced by melt-processing and is suitable for building a support structure for a three dimensional ceramic article.

23 . The feedstock of claim 7 , wherein the feedstock material is a thermoplastic filament of pre-ceramic powder configured for building the support structure at temperatures of about 160° C.-200° C. and at a speed between about 20 mm/sec and 100 mm/sec.

24 . A method of printing a three-dimensional ceramifiable article with an additive manufacturing system, the method comprising:
printing at least one build layer with the additive manufacturing system, wherein the build layer is pre-sintered; printing at least one corresponding support layer with a feedstock material comprising:
a pre-ceramic material in powder form; and
a polymeric binder.

25 . The method of claim 9 , and further comprising heating the three-dimensional ceramifiable article to remove the polymeric binder from the support layer.

26 . The method of claim 10 , and further heating the three-dimensional object to transform the build layer into a ceramic composition.

27 . The method of one of claim 9 , wherein the at least one support layer is a pre-sintered support layer, and wherein upon heating the three-dimensional object, the pre-ceramic material and at least one support layer is removable in a solvent.

28 . The method of claim 9 , wherein the polymeric binder is a matrix comprising one or more of polyolefins, polylactic acid polymers, and acrylonitrile butadiene styrene polymers or combinations thereof.

29 . The method of claim 9 , wherein the pre-ceramic material comprises calcium carbonate, sodium carbonate, sodium aluminate or combinations thereof.

30 . The method of claim 12 , wherein the solvent comprises water, carbonated solutions, acidic solutions and combinations thereof.

31 . The method of claim 9 , wherein the feedstock material is a filament configured for building a three-dimensional support structure at temperatures of about 160° C.-200° C. and at a speed between about 20 mm/sec and 100 mm/sec.

32 . The method of claim 9 , wherein the feedstock material further comprises one or more of a fluxing materials, a polymer processing additive or combinations thereof.

33 . A method of building a three-dimensional article with additive manufacturing wherein the article comprises at least one build layer supported by a support layer derived from a feedstock material comprising a pre-ceramic material and a polymeric binder wherein upon thermal processing of the feedstock, the pre-ceramic material is removable in a solvent.

34 . The method of claim 18 , and further comprising firing the three-dimensional article.

35 . The method of claim 19 , and further comprising removing the support layer by the solvent.

Assignees

• Stratasys Inc
• Stratasys Inc

Inventors

• Demuth Benjamin A
• Pawloski Adam R

Classifications

• C04B2235/94

  Products characterised by their shape · CPC title

• C04B38/04

  by dissolving-out added substances · CPC title

• C04B35/62695

  Granulation or pelletising (devices for shaping artificial aggregates from ceramic mixtures B28B1/004) · CPC title

• C04B2111/40

  Porous or lightweight materials · CPC title

• D01F1/02

  Addition of substances to the spinning solution or to the melt (addition of substances to viscose D01F2/08) · CPC title