Method and Apparatus for 3d Printing of Nano-Filler/Polymer Composites

Patent metadata

Field	Value
Publication number	US-2016297142-A1
Application number	US-201615094967-A
Country	US
Kind code	A1
Filing date	Apr 8, 2016
Priority date	Apr 8, 2015
Publication date	Oct 13, 2016
Grant date	—

Abstract

An apparatus and method for printing an object via additive manufacturing is disclosed. In accordance with an illustrative embodiment, one or more inks are prepared, including a thermo-polymer ink, a nano-filler ink, and a thermo-polymer/nano-filler ink. In some embodiments, an object is printed by depositing alternating layers of thermo-polymer ink and nano-filler ink and exposing the layers to microwave radiation. In some other embodiments, an object is printed by depositing alternating layers of thermo-polymer/nano-filler ink and nano-filler ink and exposing the layers to microwave radiation. In some additional embodiments, an object is printed by depositing successive layers of thermo-polymer/nano-filler ink and exposing them to microwave radiation.

First claim

What is claimed:

1 . A method for printing an object via additive manufacturing, the process comprising:
depositing a first layer, the first layer comprising droplets of a first ink, wherein the first ink comprises thermo-polymer particles in a first suspension medium; depositing a second layer on at least a portion of the first layer, wherein the second layer comprises droplets of a second ink, wherein the second ink comprises first nano-filler in a second suspension medium; depositing a third layer on at least a portion of the second layer, wherein the third layer comprises droplets of the first ink; and exposing the first, second and third layers to microwave radiation.

2 . The method of claim 1 and further wherein the first ink further comprises second nano-filler.

3 . The method of claim 2 wherein the first nano-filler and the second nano-filler comprise different materials.

4 . The method of claim 1 wherein the first nano-filler comprises carbon nanotubes.

5 . The method of claim 1 and further wherein prior to exposing the first, second, and third layers to microwave radiation, the method further comprises sintering the first layer by exposing it to laser light.

6 . The method of claim 1 wherein depositing a first layer further comprises ultrasonically dispersing:
(a) the thermo-polymer in the first suspension medium; and
(b) the nano-filler in the second suspension medium.

7 . The method of claim 1 wherein exposing the first, second and third layers to microwave radiation further comprises exposing the first, second and third layers to microwave radiation at a first power level then exposing the first, second and third layers to microwave radiation at a second power level, wherein the first power level is relatively greater than the second power level.

8 . The method of claim 7 further comprising exposing the first, second and third layers to microwave radiation at a third power level after exposing same at the second power level, wherein the second power level is relatively greater than the third power level.

9 . The method of claim 1 further comprising preparing the first ink by:
(a) compounding the thermo-polymer with carbon black;
(b) powderizing the compounded thermo-polymer/carbon black to produce a powder;
(c) adding the powder to the first suspension medium forming a mixture; and
(d) agitating the mixture.

10 . The method of claim 9 wherein the thermo-polymer is PEEK.

11 . The method of claim 2 further comprising preparing the first ink by:
(a) compounding the thermo-polymer with the second nano-filler;
(b) powderizing the compounded thermo-polymer/second nano-filler to produce a powder;
(c) adding the powder to the first suspension medium, thereby forming a mixture; and
(d) agitating the mixture.

12 . The method of claim 11 wherein the thermo-polymer is PEEK and the second nano-filler comprises CNTs.

13 . The method of claim 1 further comprising preparing the second ink by:
(a) adding the first nano-filler to the second suspension medium;
(b) adding a surfactant to the second suspension medium, wherein the surfactant, first nano-filler, and second suspension medium forming a mixture; and
(c) agitating the mixture.

14 . An apparatus for printing an object via additive manufacturing, the apparatus comprising:
a print head having at least one nozzle, wherein the print head dispenses at least one of: (i) a first ink comprising a thermo-polymer in a suspension medium, and (ii) a second ink comprising a nano-filler in a suspension medium; a gantry, wherein the print head is movably coupled to the gantry to enable the print head to move in at least one direction; a source of microwave radiation; and a build platform, wherein the at least first ink or second ink is dispensed from the print head to the build platform, and wherein the build platform is movable in a vertical direction.

15 . The apparatus of claim 14 wherein the source of microwave radiation is a maser.

16 . The apparatus of claim 15 wherein the maser is affixed to the print head.

17 . The apparatus of claim 15 wherein the maser is movable independently of the print head.

18 . The apparatus of claim 14 wherein the source of microwave radiation is a source of focused apparatus microwave radiation and is movable via the gantry, and further comprising a source of unfocused microwave radiation, wherein the source of unfocused microwave radiation is fixed.

19 . The apparatus of claim 14 and further comprising a laser, wherein the laser is movable via the gantry.

Assignees

• Arevo Inc

Inventors

• Bheda Hemant
• Reese Riley

Classifications

• B29C64/135 Primary

  the energy source being concentrated, e.g. scanning lasers or focused light sources · CPC title

• B29K2105/162

  Nanoparticles · CPC title

• C08K7/24 Primary

  inorganic · CPC title

• C09D11/324

  containing carbon black · CPC title

• C09D11/037

  characterised by the pigment · CPC title