Sinterable semi-crystalline powder and near-fully dense article formed therewith

  • US 5,990,268 A
  • Filed: 11/21/1996
  • Issued: 11/23/1999
  • Est. Priority Date: 11/23/1992
  • Status: Expired due to Term
First Claim
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1. A method of producing a three-dimensional object, comprising the steps of:

  • applying a layer of a powder at a target surface, said powder comprised of a semicrystalline organic polymer, said powderhaving a major portion by weight having a sphericity of at least about 0.5;

    having a particle size distribution in which a majority of the number of particles in said powder are smaller than about 53 μ

    m; and

    having a window of sinterability, defined by a difference between a caking temperature Tc of said powder and a softening temperature Ts of said powder;

    directing energy at selected locations of said layer corresponding to a cross-section of an object to be formed in said layer to sinter said powder thereat; and

    repeating said applying and directing steps to form said object in layerwise fashion.

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