Three dimensional printing material system and method using plasticizer-assisted sintering
View Patent ↗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.
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.