Three dimensional printing material system and method using plasticizer-assisted sintering

• US 7,968,626 B2
• Filed: 02/22/2008
• Issued: 06/28/2011
• Est. Priority Date: 02/22/2007
• Status: Active Grant

• Current Assignee: 3D Systems, Inc. (3D Systems Corporation)
• Original Assignee: Z CORPORATION (A Holdings Corp.)
• Inventors: Williams, Derek X., Giller, Eugene
• Primary Examiner(s): Cano; Milton I
• Assistant Examiner(s): USELDING, JOHN E
• Application Number:
  US12/035,743
• Publication Number:
  US 20080281019A1
• Time in Patent Office: 1,222 Days
• Field of Search: 524/8
• US Class Current: 524/8
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 70/10 Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

Abstract

A materials system, kit, and methods are provided to enable the formation of articles by three dimensional printing. The kit includes (i) a substantially dry particulate material including an aqueous-insoluble thermoplastic particulate material, plaster, and a water-soluble adhesive; (ii) an aqueous fluid binder, and (iii) an infiltrant.

Claims

1. A powder material system for three dimensional printing comprising:

a substantially dry particulate material including;

an aqueous-insoluble thermoplastic particulate material selected from the group consisting of a polyamide 6-3 and terephthalic acid copolymer, cyclic polyolefins, and combinations thereof,

plaster, and

a water-soluble adhesive,

wherein the dry particulate material is suitable for use in three dimensional printing to form an article comprising a plurality of layers, the layers including a reaction product of the particulate material and an aqueous fluid that contacts the particulate material during three dimensional printing.

2. The material system of claim 1, wherein a static and a dynamic friction coefficient of the particulate material possess a relationship defined by a Bredt parameter having a value in excess of 0.1.

3. The material system of claim 1, wherein an internal angle of friction of the particulate material is selected from a range of 40°

to 70°

.

4. The material system of claim 1, wherein the particulate material comprises about 5%-50% by weight of the aqueous-insoluble thermoplastic, about 25-90% by weight of the plaster, and about 5-30% by weight of the water-soluble adhesive.

5. The material system of claim 1, wherein the particulate material further comprises a processing aid.

6. A kit comprising:

a substantially dry particulate material including;

an aqueous-insoluble thermoplastic particulate material selected from the group consisting of a polyamide 6-3 and terephthalic acid copolymer, cyclic polyolefins, and combinations thereof,

plaster, and

a water-soluble adhesive;

an aqueous fluid binder; and

an infiltrant.

7. The kit of claim 6, wherein the infiltrant comprises 0-99.99% by weight hydroxylated hydrocarbon, 0-99.99% by weight a solid wax, 0-99.99% by weight a plasticizer, and 0.01-5% by weight a stabilizer.

8. The kit of claim 7, wherein the hydroxylated hydrocarbon comprises a hydrocarbon diol with a molecular weight greater than 118 g/mol, a melting point greater than 30°

C., and a kinematic viscosity of less than or equal to 150 centiStokes at a temperature of at least 50°

C.

9. The kit of claim 8, wherein the hydrocarbon diol comprises octane diol.

10. The kit of claim 8, wherein the hydrocarbon diol comprises decane diol.

11. The kit of claim 6, wherein the infiltrant comprises hydroxylated hydrocarbon including (i) a hydrocarbon diol with a molecular weight greater than 118 g/mol and a melting point greater than 30°

C. and (ii) a plasticizer.

12. The kit of claim 11, wherein the hydroxylated hydrocarbon comprises decane diol.

13. The kit of claim 11, wherein the plasticizer comprises benzene sulfonamide.

14. The kit of claim 11, wherein the plasticizer comprises propylene carbonate.

15. The kit of claim 7, wherein the hydroxylated hydrocarbon comprises an alcohol having a boiling point selected from a range of 25°

C. to 100°

C., and the plasticizer has a boiling point selected from a range of 25°

C. to 100°

C.

16. The kit of claim 15, wherein the alcohol comprises isopropanol.

17. The kit of claim 15, wherein the plasticizer comprises ethanol.

18. The kit of claim 7 wherein the infiltrant comprises 69.99-99.99% by weight hydroxylated hydrocarbon, 0-30% by weight a plasticizer, and 0.01-5% by weight a stabilizer.

19. The kit of claim 7 wherein the infiltrant comprises 79.99-99.99% by weight solid wax, 0-20% by weight a plasticizer, and 0.01-5% by weight a stabilizer.

20. The kit of claim 6 wherein the infiltrant comprises 30-100% by weight fugitive hydroxylated hydrocarbon, 0-50% by weight a solvent, and 0-30% by weight a plasticizer.