Additive manufacturing compositions and methods for the same

Patent metadata

Field	Value
Publication number	US-2021283837-A1
Application number	US-202016816105-A
Country	US
Kind code	A1
Filing date	Mar 11, 2020
Priority date	Mar 11, 2020
Publication date	Sep 16, 2021
Grant date	—

Abstract

Additive manufacturing compositions and methods for fabricating a conductive article with the same are provided. The additive manufacturing composition may include a 3D printable material and a metal precursor disposed in the 3D printable material. The metal precursor may include a metal salt, a metal particle, or combinations thereof. The method may include forming a first layer of the article on a substrate, where the first layer includes the additive manufacturing composition, forming a second layer of the article adjacent the first layer, and binding the first layer with the second layer to fabricate the article. The method may also include plating a metal on at least a portion of the article to fabricate the conductive article.

First claim

What is claimed is:

1 . An additive manufacturing composition for fabricating a conductive article, comprising:
a 3D printable material; and a metal precursor disposed in the 3D printable material, wherein the metal precursor comprises a metal salt, a metal particle, or combinations thereof.

2 . The additive manufacturing composition of claim 1 , wherein the 3D printable material comprises at least one water insoluble polymer.

3 . The additive manufacturing composition of claim 1 , wherein the 3D printable material comprises one or more of acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), thermoplastic polyurethane (TPU), polystyrene, polypropylene (PP), polyethylene (PE), ethylene vinyl acetate (EVA), thermoplastic polyolefin (TPO), rubber, nylon, polycaprolactone (PCL), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PTG), polyamide, aromatic polyamide, polyether, polyester, polymethylmethacrylate (PMMA), polyurethane copolymers, ethylene vinyl alcohol, or combinations thereof.

4 . The additive manufacturing composition of claim 3 , wherein the 3D printable material is selected from the group consisting of PLA, PCL, ABS, and combinations thereof.

5 . The additive manufacturing composition of claim 1 , wherein the metal precursor comprises the metal salt, and wherein the metal salt comprises a metal cation selected from the group consisting of a nickel cation, a zinc cation, a tin cation, a platinum cation, copper cation, a palladium cation, a silver cation, a gold cation, an aluminum cation, an iron cation, a magnesium cation, and combinations thereof.

6 . The additive manufacturing composition of claim 1 , wherein the metal salt comprises an anion selected from the group consisting of an acetylacetonate, 2-ethylhexanoate, phthalocyanine, fluoride, chloride, bromide, iodide, sulfide, nitrate, phosphate, carbonate, oxalate, formate, sulfate, triflate, bis(trifluoromethyl)sulfonimide, tetrafluoroborate, hexafluorophosphate, and combinations thereof.

7 . The additive manufacturing composition of claim 1 , wherein the metal salt comprises one or more of copper (II) acetylacetonate (Cu(O 2 C 5 H 7 ) 2 ), copper sulfate (CuSO 4 □5H 2 O), copper chloride, copper citrate, copper acetate, copper phosphate (Cu 3 (PO 4 ) 2 ), gold chloride (AuCl), gold bromide (AuBr), gold iodide (AuI), tetrabromoauric acid (HAuBr 4 ), tetrachloroauric acid (HAuCl 4 ), palladium sulfate, (PdSO 4 □7H 2 O), palladium chloride, palladium nitrate, palladium acetate, palladium 2,4-pentanedionate, or combinations thereof.

8 . The additive manufacturing composition of claim 1 , wherein the composition consists of the 3D printable material and the metal precursor.

9 . The additive manufacturing composition of claim 8 , wherein the 3D printable material consists of polylactic acid and the metal precursor consists of copper (II) acetylacetonate (Cu(O 2 C 5 H 7 ) 2 ).

10 . The additive manufacturing composition of claim 1 , wherein the additive manufacturing composition is a 3D printable filament.

11 . The additive manufacturing composition of claim 1 , wherein the additive manufacturing composition is a 3D printable powder.

12 . The additive manufacturing composition of claim 1 , wherein the additive manufacturing composition is a 3D printable resin.

13 . The additive manufacturing composition of claim 1 , wherein the metal precursor comprises the metal particle, and wherein the metal particle comprises one or more of copper particles, silver particles, gold particles, aluminum particles, magnesium particles, manganese particles, iron particles, nickel particles, zinc particles, tin particles, platinum particles, palladium particles, or combinations thereof.

14 . A method for fabricating a conductive article, the method comprising:
forming a first layer of an article on a substrate, the first layer comprising the additive manufacturing composition of claim 1 ; forming a second layer of the article adjacent the first layer; binding the first layer with the second layer to fabricate the article; and plating a metal on at least a portion of the article to fabricate the conductive article.

15 . The method of claim 14 , further comprising activating the metal precursors of the additive manufacturing composition with a reducing agent.

16 . The method of claim 14 , wherein plating the metal on at least a portion of the article comprises an electroless plating process.

17 . The method of claim 16 , wherein the electroless plating process further comprises depositing metal on or about the activated metal precursors.

18 . The method of claim 14 , wherein the second layer comprises a water soluble polymer.

19 . The method of claim 14 , wherein the second layer comprises a 3D printable material substantially free of any metal precursors.

20 . The method of claim 14 , further comprising:
generating a digital model of the article with a computer aided design assembly; and partitioning the digital model into at least a first digital cross-section and a second digital cross-section, wherein forming the first layer of the article on the substrate comprises forming the first layer of the article on the substrate using the first digital cross-section as a first template; and wherein forming the second layer of the article adjacent the first layer comprises forming the second layer of the article adjacent the first layer using the second digital cross-section as a second template.

21 . The method of claim 14 , wherein the conductive article comprises a conductivity of at least 1E6 Siemens per meter (S/m).

22 . A kit for additive manufacturing of a conductive article, the kit comprising:
the additive manufacturing composition of claim 1 ; an activation solution comprising a reducing agent and configured to activate the metal precursor of the additive manufacturing composition; and a deposition solution configured to deposit metal on or about the activated metal precursor.

Assignees

• Palo Alto Res Ct Inc

Inventors

• Wei Junhua
• Plochowietz Anne
• Evans Kent
• Doris Sean E

Classifications

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• C23C18/42

  Coating with noble metals · CPC title

• C23C18/405

  Formaldehyde · CPC title

• C23C18/1635

  Composition of the substrate · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title