Surface modified particulate and sintered or injection molded products
First Claim
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1. An article adapted for use in an additive manufacturing system, the system comprising a digitally controlled applicator that can deposit a filament in a controlled x-y plane and in a z-direction filament application to obtain a pre-form object;
- the article comprising a filament, having a diameter of about 0.1 to 3 millimeters, comprising a thermoplastic composite comprising;
(a) about 70 to 1 wt. % of a thermoplastic polymer; and
(b) about 99 to 30 wt. % of a metal particulate, dispersed in the polymer, particulate having a particle size of less than 500 microns, and the particulate having exterior coating of interfacial modifier in an amount of about 0.005 to 10.0 wt. %, all percentages based on the weight of the filament.
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Abstract
Disclosed are interfacially modified particulate and polymer composite material for use in injection molding processes, such as metal injection molding and additive process such as 3D printing. The composite material is uniquely adapted for powder metallurgy processes. Improved products are provided under process conditions through surface modified powders that are produced by extrusion, injection molding, additive processes such as 3D printing, Press and Sinter, or rapid prototyping.
45 Citations
23 Claims
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1. An article adapted for use in an additive manufacturing system, the system comprising a digitally controlled applicator that can deposit a filament in a controlled x-y plane and in a z-direction filament application to obtain a pre-form object;
- the article comprising a filament, having a diameter of about 0.1 to 3 millimeters, comprising a thermoplastic composite comprising;
(a) about 70 to 1 wt. % of a thermoplastic polymer; and (b) about 99 to 30 wt. % of a metal particulate, dispersed in the polymer, particulate having a particle size of less than 500 microns, and the particulate having exterior coating of interfacial modifier in an amount of about 0.005 to 10.0 wt. %, all percentages based on the weight of the filament. - View Dependent Claims (2, 3, 4, 5, 6, 7)
- the article comprising a filament, having a diameter of about 0.1 to 3 millimeters, comprising a thermoplastic composite comprising;
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8. An article adapted for use in an additive manufacturing system, the system comprising a digitally controlled applicator that can deposit a filament in a controlled x-y plane with subsequent z-direction filament application to obtain a pre-form object;
- the article comprising filament having a diameter of about 0.11 to 3 millimeters, the filament comprising a thermoplastic composition comprising;
(a) about 70 to 1 wt. % of a thermoplastic polymer; and (b) about 99 to 30 wt. % of a particulate selected from a ceramic particulate, an inorganic particulate or a glass particulate dispersed in the polymer, particulate having a particle size of less than 500 microns; and
the particulate having an exterior coating of interfacial modifier in an amount of about 0.005 to 10.0 wt. %, all percentages based on the weight of the filament. - View Dependent Claims (9, 10, 11, 12, 13, 14)
- the article comprising filament having a diameter of about 0.11 to 3 millimeters, the filament comprising a thermoplastic composition comprising;
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15. An article adapted for use in an additive manufacturing system, the system comprising a digitally controlled applicator that can deposit a filament in a controlled x-y plane and in a z-direction filament application to obtain a pre-form object;
- the article comprising a filament, having a diameter of about 0.1 to 3 millimeters, comprising a thermoplastic composite comprising;
(a) about 70 to 1 wt. % of a thermoplastic polymer; and (b) about 99 to 50 wt. % of a metal particulate comprising copper, iron or titanium, dispersed in the polymer, particulate having a particle size of 4 to 200 microns, and the particulate having exterior coating of interfacial modifier in an amount of about 0.005 to 10.0 wt. %, all percentages based on the weight of the filament;
wherein in the filament the composite has a volume packing greater than 75%. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23)
- the article comprising a filament, having a diameter of about 0.1 to 3 millimeters, comprising a thermoplastic composite comprising;
Specification