Three-dimensional printing

Patent metadata

Field	Value
Publication number	US-2024246147-A1
Application number	US-202418628434-A
Country	US
Kind code	A1
Filing date	Apr 5, 2024
Priority date	Oct 29, 2018
Publication date	Jul 25, 2024
Grant date	—

Abstract

In an example of a method for three-dimensional printing, a first amount of a binding agent is selectively applied, based on a 3D object model, to individual build material layers of a particulate build material including metal particles to forming an intermediate structure. The binding agent and/or a void-formation agent is selectively applied, based on the 3D object model, to at least one interior layer of the individual build material layers so that a total amount of the binding agent, the void-formation agent, or both the binding agent and the void-formation agent in the at least one of the individual build material layers is greater than the first amount. This patterns an area that is to contain voids. The intermediate structure is heated to form a 3D structure including a void-containing breakable connection.

First claim

1 .- 7 . (canceled)

8 . A method for three-dimensional printing, comprising:
patterning build material layers of a particulate build material including metal particles to form an intermediate structure, the patterning including:
selectively applying a first amount of a binding agent to define: a build material support structure and a patterned intermediate part; and
selectively applying the binding agent to define a patterned breakable connection between at least a portion of the build material support structure and at least a portion of the patterned intermediate part, wherein a second amount of the binding agent in the patterned breakable connection is greater than the first amount; and
heating the intermediate structure to form i) a 3D object from the patterned intermediate part, ii) a 3D support structure from the build material support structure, and iii) a void-containing breakable connection from the patterned breakable connection at an area of the intermediate structure patterned with the binding agent in the second amount.

9 . The method as defined in claim 8 wherein:
each of the build material layers has a thickness ranging from about 30 μm to about 120 μm;
the first amount ranges from about 0.12 grams per square meter (gsm) per 1 μm of build material layer thickness to about 0.26 gsm per 1 μm of build material layer thickness; and
the second amount ranges from about 0.3 gsm per 1 μm of build material layer thickness to about 0.6 gsm per 1 μm of build material layer thickness.

10 . The method as defined in claim 8 , further comprising removing the 3D support structure from the 3D object by breaking the void-containing breakable connection.

11 .- 15 . (canceled)

16 . The method as defined in claim 8 wherein the void-containing breakable connection includes voids, and wherein an average diameter of the voids is equal to or greater than a thickness of each of the build material layers.

17 . The method as defined in claim 8 wherein the void-containing breakable connection includes sintered metal particles.

18 . The method as defined in claim 8 wherein the binding agent includes a binder and an aqueous vehicle, and wherein the binder is selected from the group consisting of a latex, polyvinyl alcohol, polyvinylpyrrolidone, and combinations thereof.

19 . The method as defined in claim 18 wherein the binding agent further includes a co-solvent, a surfactant, an antimicrobial agent, an anti-kogation agent, or combinations thereof.

20 . The method as defined in claim 8 wherein each of the selectively applying steps is accomplished using a thermal inkjet printhead or a piezoelectric inkjet printhead.

21 . The method as defined in claim 8 wherein the 3D object formed at areas patterned with the first amount of the binder agent is free of voids.

22 . A method for three-dimensional printing, comprising:
patterning build material layers of a particulate build material including metal particles to form an intermediate structure, the patterning including:
selectively applying a first amount of a binding agent to define: a build material support structure and a patterned intermediate part; and
selectively applying both the binding agent and a void-formation agent to define a patterned breakable connection between at least a portion of the build material support structure and at least a portion of the patterned intermediate part, wherein a total amount of the binding agent and the void-formation agent in the patterned breakable connection is greater than the first amount; and
heating the intermediate structure to form i) a 3D object from the patterned intermediate part, ii) a 3D support structure from the build material support structure, and iii) a void-containing breakable connection from the patterned breakable connection at an area of the intermediate structure patterned with both the binding agent and the void-formation agent in the total amount.

23 . The method as defined in claim 22 wherein:
each of the build material layers has a thickness ranging from about 30 μm to about 120 μm;
the first amount ranges from about 0.12 grams per square meter (gsm) per 1 μm of build material layer thickness to about 0.26 gsm per 1 μm of build material layer thickness; and
the total amount ranges from about 0.3 gsm per 1 μm of build material layer thickness to about 0.6 gsm per 1 μm of build material layer thickness.

24 . The method as defined in claim 22 , further comprising removing the 3D support structure from the 3D object by breaking the void-containing breakable connection.

25 . The method as defined in claim 22 wherein the void-formation agent includes water.

26 . The method as defined in claim 22 wherein the void-containing breakable connection includes voids, and wherein an average diameter of the voids is equal to or greater than a thickness of each of the build material layers.

27 . The method as defined in claim 22 wherein the void-containing breakable connection includes sintered metal particles.

28 . The method as defined in claim 22 wherein the binding agent includes a binder and an aqueous vehicle, and wherein the binder is selected from the group consisting of a latex, polyvinyl alcohol, polyvinylpyrrolidone, and combinations thereof.

29 . The method as defined in claim 28 wherein the binding agent further includes a co-solvent, a surfactant, an antimicrobial agent, an anti-kogation agent, or combinations thereof.

30 . The method as defined in claim 22 wherein each of the selectively applying steps is accomplished using a thermal inkjet printhead or a piezoelectric inkjet printhead.

31 . The method as defined in claim 22 wherein the 3D object formed at areas patterned with the first amount of the binder agent is free of voids.

Assignees

• Hewlett Packard Development Co

Inventors

• Hower Jason C
• Shaarawi Mohammed S
• Kasperchik Vladek P
• Mckinnell James
• Wu Jennifer L

Classifications

• B22F1/107

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

• B22F10/47

  characterised by structural features · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B22F3/1021

  Removal of binder or filler (removal of binder from ceramics C04B35/638) · CPC title

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title