Additive manufactured articles having passivated surfaces and related methods
Some embodiments relate to additive manufactured articles having passivated surfaces and related methods. The methods may comprise forming a three-dimensional (3D) article by additive manufacturing to obtain an additive manufactured 3D article comprising a magnesium component. The method may further comprise exposing the additive manufactured 3D article to a reactive gas phase comprising a fluorine component. The fluorine component from the reactive gas phase may react with the magnesium component of the additive manufactured 3D article to form a passivation layer at and below a surface of the additive manufacture 3D article.
1 . A method for forming an article comprising: forming a three-dimensional (3D) article by additive manufacturing to obtain an additive manufactured 3D article, wherein the additive manufactured 3D article comprises a magnesium component; and exposing the additive manufactured 3D article to a reactive gas phase to form a passivation layer, wherein the reactive gas phase comprises a fluorine component, wherein the fluorine component reacts with the magnesium component to form magnesium fluoride at and below a surface of the additive manufactured 3D article, and wherein the magnesium fluoride covers at least 90% of gas-exposed surfaces of the additive manufactured 3D article.
2 . The method according to claim 1 , wherein the forming comprises dispensing a 3D printable material from a 3D printer to form the additive manufactured 3D article.
3 . The method according to claim 1 , wherein the magnesium component comprises at least one of a magnesium-containing metal alloy, a magnesium ion, a magnesium-containing metal oxide, elemental magnesium, or any combination thereof.
4 . The method according to claim 1 , wherein the additive manufactured 3D article has a monolithic structure that is not capable of construction by machining.
5 . The method according to claim 1 , wherein the additive manufactured 3D article is an article of unitary construction.
6 . The method according to claim 1 , wherein the additive manufactured 3D article comprises at least one of a plenum, a trench, a structure defining a hole, a structure defining a channel, a structure defining a cavity, or any combination thereof.
7 . The method according to claim 1 , wherein the additive manufactured 3D article has an aspect ratio of 2:1 to 1000:1, wherein the aspect ratio is a ratio of two of a width, a depth, a height, or a diameter.
8 . The method according to claim 1 , wherein the additive manufactured 3D article does not comprise seams.
9 . The method according to claim 1 , wherein the additive manufactured 3D article does not comprise braze joints.
10 . The method according to claim 1 , wherein the additive manufactured 3D article does not comprise weld joints.
11 . The method according to claim 1 , wherein the reactive gas phase comprises at least one of CF 4 , C 2 F 4 , C 3 F 6 , C 4 F 8 , CHF 3 , C 2 H 2 F 2 , C 2 F 6 , HF, CH 3 F, or any combination thereof.
12 . The method according to claim 1 , wherein the reactive gas phase is derived from at least one of polymerized perfluoroalkylethylene having a C 1 -C 10 perfluoroalkyl group; polytetrafluoroethylene (PTFE); tetrafluoroethylene/perfluoro (alkyl vinyl ether) copolymer (PFA); tetrafluoroethylene/hexafluoropropylene copolymer (FEP); tetrafluoroethylene/perfluoro (alkyl vinyl ether)/hexafluoropropylene copolymer (EPA); polyhexafluoropropylene; ethylene/tetrafluoroethylene copolymer (ETFE); poly trifluoroethylene; polyvinylidene fluoride (PVDF); polyvinyl fluoride (PVF); polychlorotrifluoroethylene (PCTFE); ethylene/chlorotrifluoroethylene copolymer (ECTFE); or any combination thereof.
13 . The method of claim 1 , wherein the article is a medical device.