Binder compositions for additive manufacturing comprising low molecular weight polymers including acrylic acid repeat units

Patent metadata

Field	Value
Publication number	US-2025128326-A1
Application number	US-202418671021-A
Country	US
Kind code	A1
Filing date	May 22, 2024
Priority date	Oct 21, 2019
Publication date	Apr 24, 2025
Grant date	—

Abstract

Methods of additive manufacturing, binder compositions for additive manufacturing, and articles produced by and/or associated with methods of additive manufacturing are generally described.

First claim

What is claimed is:

1 - 41 . (canceled)

42 . A binder composition for additive manufacturing of metal objects by binder jetting, the binder composition comprising:
water; a low molecular weight polymer including an acrylic acid repeat unit; a cross-linking agent comprising a polyol, a multifunctional amine, and/or a multifunctional thiol; and a pH modifier.

43 . The binder composition of claim 42 , wherein the low molecular weight polymer has a weight average molecular weight of less than or equal to 40 kDa.

44 . The binder composition of claim 42 , wherein the low molecular weight polymer has a weight average molecular weight of less than or equal to 6 kDa.

45 . The binder composition of claim 42 , wherein the binder composition has a viscosity of less than or equal to 20 cP at a printing temperature.

46 . The binder composition of claim 42 , wherein the wt % of the low molecular weight polymer in the binder composition is greater than or equal to 1 wt % and less than or equal to 40 wt %.

47 . The binder composition of claim 42 , wherein the wt % of the low molecular weight polymer in the binder composition is greater than or equal to 1 wt % and less than or equal to 25 wt %.

48 . The binder composition of claim 42 , wherein the pH of the binder composition is greater than or equal to 7.

49 . The binder composition of claim 42 , wherein the pH of the binder composition is greater than or equal to 4.

50 . The binder composition of claim 42 , wherein the pH modifier has a boiling point of less than or equal to 150° C.

51 . The binder composition of claim 42 , wherein the pH modifier is configured to be removed from the binder composition before the onset of a cross-linking reaction between the polymer including the acrylic acid repeat unit and the cross-linking agent.

52 . A three-dimensional composition formed by additive manufacturing, the composition comprising:
a metal powder; and a binder composition, wherein the binder composition comprises:
water;
a low molecular weight polymer including an acrylic acid repeat unit;
a cross-linking agent comprising a polyol, a multifunctional amine, and/or a multifunctional thiol; and
a pH modifier.

53 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the metal powder is a steel powder.

54 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the low molecular weight polymer has a weight average molecular weight of less than or equal to 40 kDa.

55 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the low molecular weight polymer has a weight average molecular weight of less than or equal to 6 kDa.

56 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the binder composition has a viscosity of less than or equal to 20 cP at a printing temperature.

57 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the wt % of the low molecular weight polymer in the binder composition is greater than or equal to 1 wt % and less than or equal to 40 wt %.

58 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the wt % of the low molecular weight polymer in the binder composition is greater than or equal to 1 wt % and less than or equal to 25 wt %.

59 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the metal powder comprises a ferrous alloy having a chromium content of less than or equal to 2 wt %, and wherein the pH of the binder composition is greater than or equal to 7.

60 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the metal powder comprises a ferrous alloy having a chromium content of greater than or equal to 2 wt %, and wherein the pH of the binder composition is greater than or equal to 4.

61 . The three-dimensional composition formed by additive manufacturing of claim 52 , wherein the pH modifier has a boiling point of less than or equal to 150° C.

62 - 72 . (canceled)

Assignees

• Desktop Metal Inc

Inventors

• Renner Christopher Benjamin
• Rushkin Llya L
• Sachs Emanuel M

Classifications

• B22F1/10

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

• B33Y70/00 Primary

  Materials specially adapted for additive manufacturing · CPC title

• B29K2033/04

  Polymers of esters · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29K2105/24

  crosslinked or vulcanised · CPC title