Compositions for three-dimensional (3D) printing

1. A composition for three-dimensional printing, the composition comprising:

a liquid, curable, cross-linkable monomer;

solid thermoplastic particles mixed with the liquid, curable, cross-linkable monomer, the solid thermoplastic particles consisting of i) a homopolymer selected from the group consisting of polyethylene, oxidized polyethylene, and polypropylene, or of ii) milled polycarbonate, or of iii) milled acrylonitrile butadiene styrene, and having a size ranging from about 200 nm to about 50 μm; and

a light sensitive initiator mixed with the liquid, curable, cross-linkable monomer.

2. The composition as defined in claim 1 wherein an amount of the solid thermoplastic particles present in the composition is 80 wt. % or less of a total wt. % of the composition.

3. A composition for three-dimensional printing, the composition comprising:

a liquid, curable, cross-linkable monomer;

solid thermoplastic particles mixed with the liquid, curable, cross-linkable monomer, the solid thermoplastic particles:

having a size ranging from about 200 nm to about 50 μm;

being formed of a heteropolymer of styrene, octadecyl acrylate, methacrylonitrile, and ethylene glycol dimethacrylate; and

having a glass transition temperature (T g ) ranging from about 80° C. to about 150° C.; and

a light sensitive initiator mixed with the liquid, curable, cross-linkable monomer.

4. The composition as defined in claim 1 , further comprising a catalyst.

5. The composition as defined in claim 1 wherein:

the light sensitive initiator is sensitive to wavelengths ranging from 400 nm to 600 nm; and

the light sensitive initiator is present in an amount ranging from about 0.1 wt. % of a wt. % of the liquid, curable, cross-linkable monomer to about to about 5 wt. % of the wt. % of the liquid, curable, cross-linkable monomer.

6. A three-dimensional printing method, comprising:

applying the composition as defined in claim 1 as a film on a surface; and

exposing the film to light, thereby polymerizing the liquid, curable, cross-linkable monomer and forming a solidified layer of a three-dimensional product.

7. The three-dimensional printing method as defined in claim 6 wherein the composition is applied so that the film has a thickness ranging from about 20 μm to about 500 μm.

8. The three-dimensional printing method as defined in claim 6 , further comprising heating the solidified layer to a predetermined temperature for a predetermined time.

9. A method for making the solid thermoplastic particles as defined in claim 3 , the method comprising:

exposing a solid thermoplastic particle precursor to a mixing process, wherein the solid thermoplastic particle precursor is a monomer emulsion of the styrene, the octadecyl acrylate, the methacrylonitrile, and the ethylene glycol dimethacrylate in water; and

exposing the solid thermoplastic particle precursor to a predetermined temperature.

10. The method as defined in claim 9 wherein:

the mixing process includes mixing the monomer emulsion with an initiator solution to form a reaction mixture; and

the reaction mixture is exposed to the predetermined temperature for a predetermined time to form the solid thermoplastic particles.

11. The method as defined in claim 10 wherein the solid thermoplastic particles are formed in the water, and wherein the method further comprises:

removing the solid thermoplastic particles from the water; and

exposing the solid thermoplastic particles to a size reduction process to obtain particles having a size ranging from about 200 nm to about 50 μm.

12. A method for making the solid thermoplastic particles as defined in claim 1 , the method comprising:

exposing a solid thermoplastic particle precursor to a mixing process, wherein the solid thermoplastic particle precursor is a mixture of i) a carrier and acrylonitrile butadiene styrene solids or ii) a carrier and polycarbonate solids, the acrylonitrile butadiene styrene solids or polycarbonate solids being in powder form, filament form, or sheet form; and

exposing the solid thermoplastic particle precursor to a predetermined temperature;

wherein the mixing process includes:

introducing the mixture into a grinding container;

introducing grinding beads into the grinding container with the mixture;

grinding the mixture at a rotation frequency ranging from about 100 rpm to about 10,000 rpm for a time ranging from about 30 minutes to about 90 minutes;

wherein the predetermined temperature is maintained to less than 50° C. during the grinding; and

wherein after the grinding, the method further comprises removing the carrier and the grinding beads to obtain aggregates of acrylonitrile butadiene styrene or aggregates of polycarbonate.

13. The method as defined in claim 12 , further comprising exposing the aggregates of acrylonitrile butadiene styrene or the aggregates of polycarbonate to a size reduction process to obtain particles having a particle size within a range of from about 200 nm to about 50 μm.

14. The composition as defined in claim 1 wherein the liquid, curable, cross-linkable monomer is selected from the group consisting of triethylene glycol dimethacrylate, triethylene glycol diacrylate, di(ethylene glycol) dimethacrylate, tetraethylene glycol diacrylate, ethylene glycol dimethacrylate, di(ethylene glycol) divinyl ether, bisphenol A glycerate dimethacrylate, and vinyl terminated polydimethlsiloxane.

15. A composition for three-dimensional printing, the composition consisting of:

a liquid, curable, cross-linkable monomer;

solid thermoplastic particles mixed with the liquid, curable, cross-linkable monomer, the solid thermoplastic particles formed of a single homopolymer or a single heteropolymer and having a size ranging from about 200 nm to about 50 μm;

a light sensitive initiator mixed with the liquid, curable, cross-linkable monomer; and

optionally a catalyst.

16. The composition as defined in claim 15 wherein:

the solid thermoplastic particles are selected from the group consisting of ethylene resins, propylene resins, acrylic resins, polyamide resins, polyurethane resins, milled acrylonitrile butadiene styrene, milled polycarbonate, and combinations thereof; and

the liquid, curable, cross-linkable monomer is selected from the group consisting of acrylate monomers, urethane monomers, epoxy monomers, siloxane monomers, and combinations thereof.