Material system for use in three dimensional printing

• US 7,049,363 B2
• Filed: 05/30/2001
• Issued: 05/23/2006
• Est. Priority Date: 05/30/2000
• Status: Expired due to Fees

• Current Assignee: Daimler AG (Mercedes-Benz Group AG)
• Original Assignee: Daimler AG (Mercedes-Benz Group AG)
• Inventors: Shen, Jialin
• Primary Examiner(s): Cain, Edward J.
• Application Number:
  US09/870,286
• Publication Number:
  US 20020016387A1
• Time in Patent Office: 1,819 Days
• Field of Search: 524/500, 524/502, 524/530, 524/548
• US Class Current: 524/500
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing

Abstract

A material system for use in a 3D-printing, which exhibits a higher form stability. The material system contains binder and solvent as well as optional filler materials. The binder is soluble in the solvent, as well as two complementary polyelectrolytes, and/or an initiator for a cross linking reaction of the binder. The advantage of such a mixed material system is comprised in the essentially higher binder force between the individual particles. This enhanced binder force results either from the acid-base linkages, which form between the complementary polyelectrolytes, or from the supplemental networking initiated by the initiators, or from both. Substantially higher binding forces between the individual particles means at the same time a substantially higher shape stability of the 3D-printing product.

Claims

1. A two or more component material system for use in 3D-printing comprising:

a first component comprising a liquid solvent,

a second component separate from said first component and comprising dry particles comprising binder soluble in the solvent, and

optionally, filler materials in the form of particles as a third component or in said first or second component,

wherein the material system further contains two complementary polyelectrolytes and/or an initiator for a crosslinking reaction of the binder, and

wherein the two complementary polyelectrolytes are contained separately in

(i) two binders, respectively, or

(ii) in a binder and in the solvent.

2. A material system according to claim 1, wherein the initiator is contained in the solvent or in the one or both binders.

3. A material system according to claim 2, wherein the initiator is a photoinitiator.

4. A material system according to claim 1, wherein the filler particles are coated with the binder.

5. A material system according to claim 1, wherein the material system is residual-ash-poor.

6. A material system according to claim 1, wherein the material system following 3D-printing is flowable in an autoclave.

7. A material system according to claim 1, wherein at least a substantial portion of the filler material and binder particles is in the form of rounded-off particles.

8. A material system according to claim 7, wherein average particle diameter of said particles is smaller than approximately 40 μ

m.

10. A material system according to claim 1, wherein the filler material is comprised of metal, ceramic or carbide.

11. A material system according to claim 1, wherein the binder is comprised of a water-soluble polymer.

12. A material system according to claim 11, wherein the water-soluble polymer is PVP or a copolymer thereof.

9. A two or more component material system for use in 3D-printing comprising:

a first component comprising a solvent,

a second component comprising binder particles soluble in the solvent, and

optionally, filler materials in the form of particles as a third component or in said first or second component,

wherein the material system contains two complementary polyelectrolytes and/or an initiator for a crosslinking reaction of the binder, and

wherein the filler material is comprised of wax, PS, PMMA or POM.

13. A two or more component material system for use in 3D-printing comprising:

a first component comprising a liquid solvent,

a second component separate from said first component and comprising dry particles comprising binder soluble in the solvent, and

optionally, filler materials in the form of particles as a third component or in said first or second component,

wherein the material system further contains two complementary polyelectrolytes and/or an initiator for a crosslinking reaction of the binder, and

wherein the binder comprises less than 10 weight percent of the material system.

14. A process for producing a three dimensional shape, the process comprising:

(a) providing a layer of solvent-soluble dry particles comprising binder and, optionally, filler materials,

(b) printing said layer with a liquid solvent in a pattern to activate said binder,

(c) repeating steps (a) and (b) until said three-dimensional shape is formed,

wherein the material system comprised of binder, solvent and optionally filler materials contains two complementary polyelectrolytes and/or an initiator for a crosslinking reaction of the binder.