Surface modified particulate and sintered or injection molded products
First Claim
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1. A method of making a shaped metal or inorganic object with an additive manufacturing system, the method comprisesdepositing successive layers of a filament on a build bed or a platform;
- forming a shape from a digital model, the system comprising a digitally controlled applicator, in a controlled x-y plane with z-direction filament application to obtain a preform object;
the filament comprising a composite of about 70 to 1 wt. % of a thermoplastic polymer; and
about 99 to 30 wt. % of a particulate, dispersed in the polymer, the particulate having a particle size of less than 500 microns and an exterior coating of interfacial modifier on the particulate in an amount of about 0.02 to 2.0 wt. %, all percentages based on the weight of the composite; and
sintering the preform object to remove the polymer and to bond the particulate forming the shaped metal or inorganic object;
wherein the particulate comprises a metal alloy particle, an inorganic particle, a ceramic particle, a bi-metal particle or blends thereof.
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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.
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Citations
14 Claims
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1. A method of making a shaped metal or inorganic object with an additive manufacturing system, the method comprises
depositing successive layers of a filament on a build bed or a platform; -
forming a shape from a digital model, the system comprising a digitally controlled applicator, in a controlled x-y plane with z-direction filament application to obtain a preform object;
the filament comprising a composite of about 70 to 1 wt. % of a thermoplastic polymer; and
about 99 to 30 wt. % of a particulate, dispersed in the polymer, the particulate having a particle size of less than 500 microns and an exterior coating of interfacial modifier on the particulate in an amount of about 0.02 to 2.0 wt. %, all percentages based on the weight of the composite; andsintering the preform object to remove the polymer and to bond the particulate forming the shaped metal or inorganic object;
wherein the particulate comprises a metal alloy particle, an inorganic particle, a ceramic particle, a bi-metal particle or blends thereof. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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Specification