PIEZOELECTRIC POWDER PARTICULATES FOR ADDITIVE MANUFACTURING AND METHODS ASSOCIATED THEREWITH

1 . A particulate composition comprising:

a plurality of powder particulates comprising a thermoplastic polymer and a plurality of piezoelectric particles, wherein the piezoelectric particles are located (i) in the thermoplastic polymer at an outer surface of the powder particulates, (ii) within a core of the powder particulates, or (iii) combinations thereof.

2 . The particulate composition of claim 1 , further comprising:

a plurality of nanoparticles disposed upon the outer surface of each of the plurality of powder particulates, the plurality of nanoparticles comprising a plurality of oxide nanoparticles, carbon black, carbon nanotubes, graphene, or any combination thereof.

3 . The particulate composition of claim 2 , wherein the plurality of oxide nanoparticles comprises a plurality of silica nanoparticles.

4 . The particulate composition of claim 1 , wherein the piezoelectric particles are substantially non-agglomerated.

5 . (canceled)

6 . The particulate composition of claim 1 , wherein the piezoelectric particles have an average particle size of about 10 microns or less.

7 . The particulate composition of claim 1 , wherein the powder particulates comprise about 5 vol. % to about 85 vol. % piezoelectric particles.

8 . (canceled)

9 . The particulate composition of claim 1 , wherein the piezoelectric particles comprise a piezoelectric material selected from the group consisting of lead zirconate titanate, doped lead zirconate titanate, barium titanate, lead titanate, lead magnesium niobate, lead magnesium niobate-lead titanate, sodium potassium niobate, calcium copper titanate, bismuth sodium titanate, gallium phosphate, quartz, tourmaline and any combination thereof.

10 . The particulate composition of claim 1 , wherein the powder particulates range from about 1 μm to about 500 μm in size.

11 . (canceled)

12 . (canceled)

13 . (canceled)

14 . (canceled)

15 . (canceled)

16 . (canceled)

17 . (canceled)

18 . An additive manufacturing process comprising:

depositing in a powder bed a particulate composition comprising a plurality of powder particulates comprising a thermoplastic polymer and a plurality of piezoelectric particles, wherein the piezoelectric particles are located (i) in the thermoplastic polymer at an outer surface of the powder particulates, (ii) within a core of the powder particulates, or (iii) combinations thereof; and

consolidating a portion of the plurality of powder particulates in the powder bed to form a printed object.

19 . The additive manufacturing process of claim 18 , wherein the plurality of powder particulates further comprise a plurality of nanoparticles disposed upon the outer surface of each of the plurality of powder particulates, the plurality of nanoparticles comprising a plurality of oxide nanoparticles, carbon black, carbon nanotubes, graphene, or any combination thereof.

20 . (canceled)

21 . The additive manufacturing process of claim 18 , wherein the piezoelectric particles are substantially non-agglomerated.

22 . The additive manufacturing process of claim 18 , wherein the piezoelectric particles have an average particle size of about 10 microns or less.

23 . (canceled)

24 . (canceled)

25 . The additive manufacturing process of claim 18 , further comprising:

poling at least a portion of the printed object.

26 . The additive manufacturing process of claim 18 , wherein the powder particulates range from about 1 μm to about 500 μm in size.

27 . A process for forming powder particulates, comprising:

providing a composite comprising a thermoplastic polymer and a plurality of piezoelectric particles distributed in the thermoplastic polymer;

combining the composite in a carrier fluid at a heating temperature at or above a melting point or softening temperature of the thermoplastic polymer;

wherein the thermoplastic polymer and the carrier fluid are substantially immiscible at the heating temperature;

applying sufficient shear to disperse the thermoplastic polymer as liquefied droplets containing the piezoelectric particles at the heating temperature;

after liquefied droplets have formed, cooling the carrier fluid to at least a temperature at which powder particulates in a solidified state form, the powder particulates comprising the thermoplastic polymer and at least a portion of the piezoelectric particles, wherein the piezoelectric particles are located (i) in the thermoplastic polymer at an outer surface of the powder particulates, (ii) within a core of the powder particulates, or (iii) combinations thereof; and

separating the powder particulates from the carrier fluid.

28 . The process of claim 27 , further comprising:

combining a plurality of nanoparticles with the composite in the carrier fluid, the plurality of nanoparticles comprising a plurality of oxide nanoparticles, carbon black, carbon nanotubes, graphene, or any combination thereof;

wherein at least a portion of the nanoparticles are disposed upon the outer surface of each of the powder particulates.

29 . (canceled)

30 . The process of claim 27 , wherein the piezoelectric particles are substantially non-agglomerated.

31 . The process of claim 27 , wherein the piezoelectric particles have an average particle size of about 10 microns or less.

32 . (canceled)

33 . (canceled)

34 . The process of claim 27 , wherein the carrier fluid comprises a silicone oil.

35 . The process of claim 27 , wherein the powder particulates range from about 1 μm to about 500 μm in size.

36 .- 44 . (canceled)