Absorbent fillers for three-dimensional printing
First Claim
Patent Images
1. A powder for three-dimensional printing, the powder comprising:
- an absorbent filler; and
a reactive filler.
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Abstract
A materials system and methods are provided to enable the formation of articles by three-dimensional printing. The materials system includes an absorbent particulate filler that facilitates absorption of infiltrants, thereby allowing the accurate definition of articles with enhanced mechanical and structural characteristics. The methods include the use of phase-change materials to bind a powder, as well as the formation of support structures to improve the control of the shape of the articles.
177 Citations
43 Claims
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1. A powder for three-dimensional printing, the powder comprising:
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an absorbent filler; and
a reactive filler. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A method for forming an article by three-dimensional printing, the method comprising:
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providing a powder comprising a plurality of adjacent particles; and
applying to at least some of the plurality of particles a phase-change material including a thermoplastic material, wherein the thermoplastic material is adapted to (i) undergo a phase change at a temperature greater than ambient temperature, and (ii) solidify at ambient temperature, thereby binding those particles to form the article. - View Dependent Claims (17, 18)
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19. A method for forming an article by three-dimensional printing, the method comprising the steps of:
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providing a powder comprising a plurality of adjacent particles, the powder comprising an absorbent filler selected from the group consisting of powdered amorphous cellulose, powdered microcrystalline cellulose, polyamide powder, porous poly-methylmethacrylate powder, ethylene-propylene-diene-monomer (EPDM) powder, zinc oxide, magnesium oxide, calcium sulfate, calcium carbonate, surface modified ultra high molecular weight polyethylene powder, surface modified high density polyethylene powder, methylenediaminomethylether polycondensate, maltodextrin, aluminum oxide, soda-lime glass, borosilicate glass, amorphous silica, aluminosilicate ceramic, clay, fly ash, silica gel, pigment grade ceramic, and combinations thereof, and applying to at least some of the plurality of particles a fluid in an amount sufficient to bond those particles together to define the article. - View Dependent Claims (20, 21, 22, 23, 24)
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25. A method for forming a substantially solid article by three-dimensional printing, the method comprising the steps of:
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providing a powder comprising a plurality of adjacent particles;
applying to at least some of the plurality of particles a fluid in an amount sufficient to bond those particles together to define a porous singular intermediate article; and
infiltrating the intermediate article with an infiltrant to define the substantially solid final article having approximately 20%-70% infiltrant by volume. - View Dependent Claims (26, 27, 28, 29, 30, 31)
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32. A method for forming a substantially solid article by three-dimensional printing, the method comprising the steps of:
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providing a powder comprising a plurality of adjacent particles;
applying to at least some of the plurality of particles a fluid in an amount sufficient to bond those particles together to define a porous singular intermediate article and a support structure adapted to support the intermediate article; and
infiltrating the intermediate article with an infiltrant to define the substantially solid final article while the intermediate article is supported by the support structure. - View Dependent Claims (33, 34, 35, 36, 37, 38)
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39. A substantially solid article comprising:
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a conglomerate of a powder, and a fluid that binds the powder to define a porous structure; and
an infiltrant disposed within the porous structure to form the substantially solid article having about 20% to about 70% infiltrant by volume, wherein the article includes a plurality of adjacent layers formed by the conglomerate, each layer having a contour defining an edge, and a final shape of the article being defined by respective edges of the layers. - View Dependent Claims (40, 41)
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42. An activating fluid for three-dimensional printing, the fluid comprising:
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a first solvent;
a second solvent; and
a biocide. - View Dependent Claims (43)
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Specification