Engineering-grade consumable materials for electrophotography-based additive manufacturing

• US 9,523,934 B2
• Filed: 07/16/2014
• Issued: 12/20/2016
• Est. Priority Date: 07/17/2013
• Status: Active Grant

• Current Assignee: Evolve Additive Solutions, Inc.
• Original Assignee: Stratasys Incorporated
• Inventors: Orrock, James E., Chillscyzn, Steven A., Martin, Trevor I.
• Primary Examiner(s): Rodee, Christopher
• Application Number:
  US14/332,566
• Publication Number:
  US 20150024316A1
• Time in Patent Office: 888 Days
• Field of Search: 430/109.1, 430/111.41
• US Class Current: 1/1
• CPC Class Codes: B29C 43/006 Pressing and sintering powders, granules or fibres
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B29C 67/24 characterised by the choice of material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/0023 improving electric conduction
• CPC Class Codes: B29K 2105/005 Heat sensitisers or absorbers
• CPC Class Codes: B29K 2105/251 Particles, powder or granules expandable particles B29K2105/046
• CPC Class Codes: B29K 2995/0094 Geometrical properties
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: G03G 13/08 using a solid developer, e.g. powder developer
• CPC Class Codes: G03G 13/16 of a toner pattern, e.g. a powder pattern
• CPC Class Codes: G03G 13/20 Fixing, e.g. by using heat
• CPC Class Codes: G03G 13/22 Processes involving a combination of more than one step according to groups G03G13/02 - G03G13/20 G03G13/01 takes precedence
• CPC Class Codes: G03G 15/08 using a solid developer, e.g. powder developer
• CPC Class Codes: G03G 15/1625 on a base other than paper
• CPC Class Codes: G03G 15/224 Machines for forming tactile or three dimensional images by electrographic means, e.g. braille, 3d printing
• CPC Class Codes: G03G 15/24 whereby at least two steps are performed simultaneously
• CPC Class Codes: G03G 2215/1695 at the second or higher order transfer point
• CPC Class Codes: G03G 9/0819 characterised by the dimensions of the particles
• CPC Class Codes: G03G 9/08757 : Polycarbonates
• CPC Class Codes: G03G 9/08764 : Polyureas; Polyurethanes
• CPC Class Codes: G03G 9/08766 : Polyamides, e.g. polyesteramides
• CPC Class Codes: G03G 9/08795 : characterised by their chemical properties, e.g. acidity, molecular weight, sensitivity to reactants
• CPC Class Codes: G03G 9/08797 : characterised by their physical properties, e.g. viscosity, solubility, melting temperature, softening temperature, glass transition temperature
• CPC Class Codes: G03G 9/09783 : Organo-metallic compounds
• CPC Class Codes: G03G 9/09791 : Metallic soaps of higher carboxylic acids

Abstract

A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material including a composition having an engineering-grade thermoplastic material and a charge control agent. The part material is provided in a powder form having a controlled particle size, and is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner.

Claims

1. A part material for printing three-dimensional parts with an electrophotography-based additive manufacturing system, the part material comprising:

a composition comprising;

a thermoplastic material having a heat deflection temperature ranging from about 100°

C. to about 150°

C. wherein the thermoplastic material comprises polycarpolactum (PA6), polyhexamethyleneadipamide (PA6,6), polyhexamethylenenonamide (PA6.9), polyhexamethylenesebacamide (PA6,10), polyamide 6/12 (PA6,12), polyenantholactum (PA7), polyundecanolactum (PA11), polylaurolactam (PA12), or mixtures thereof; and

a charge control agent;

wherein the part material is provided in a powder form having a D50 particle size ranging from about 5 micrometers to about 30 micrometers and having a particle size distribution with a D10 value, a D50 value and a D90 value wherein a D90/D50 particle size distribution and a D50/D10 particle size distribution are in a range of between about 1.0 and 1.4 and wherein the D90/D50 particle size distribution and the D50/D10 particle size distribution are within about 10% of each other; and

wherein the part material is configured for use in the electrophotography-based additive manufacturing system having a layer transfusion assembly for printing the three-dimensional parts in a layer-by-layer manner using heat and/or pressure.

2. The part material of claim 1, wherein the composition further comprises a heat absorber, wherein the heat absorber constitutes from about 0.5% by weight to about 10% by weight of the part material.

3. The part material of claim 1, wherein the D50 particle size ranges from about 10 micrometers to about 20 micrometers.

4. The part material of claim 1, wherein the charge control agent is selected from the group consisting of chromium oxy carboxylic acid complexes, zinc oxy carboxylic acid complexes, aluminum oxy carboxylic acid complexes, and mixtures thereof.

5. The part material of claim 1, wherein the charge control agent constitutes from about 0.1% by weight to about 5% by weight of the part material.

6. The part material of claim 1, wherein the composition further comprises a flow control agent constituting from about 0.1% by weight to about 10% by weight of the part material.

7. The part material of claim 1, wherein the polyamide comprises PA6;

PA6,6;

PA6,12;

PA11;

polylaurolactam (PA12), or mixtures thereof.

8. The part material of claim 1, wherein the part material is triboelectrically charged to a Q/M ratio having a negative charge or a positive charge.

9. The part material of claim 8, wherein the magnitude of the Q/M ratio ranges from about 5 micro-Coulombs/gram to about 50 micro-Coulombs/gram.

10. The part material of claim 1, wherein the part material is in an uncharged state until mixing with carrier particles.