Methods and systems for 3D printing with powders

Fang, Zhigang Zak; Sun, Pei

Advanced Search OptionsAdvanced Search queries use a traditional Term Search. For more info, see our FAQ.

All Fields:

Patent Title:

Abstract:

Assignee:

Inventor(s):

Patent Number:

Patent Classification (CPC):

All Classifications
A - human necessities
A01 - agriculture
A21 - baking
A22 - butchering
A23 - foods or foodstuffs
A24 - tobacco
A41 - wearing apparel
A42 - headwear
A43 - footwear
A44 - haberdashery
A45 - hand or travelling articles
A46 - brushware
A47 - furniture
A61 - medical or veterinary science
A62 - life-saving
A63 - sports
A99 - subject matter not otherwise provided for in this section
B - performing operations
B01 - physical or chemical processes or apparatus in general
B02 - crushing, pulverising, or disintegrating
B03 - separation of solid materials using liquids or using pneumatic tables or jigs
B04 - centrifugal apparatus or machines for carrying-out physical or chemical processes
B05 - spraying or atomising in general
B06 - generating or transmitting mechanical vibrations in general
B07 - separating solids from solids
B08 - cleaning
B09 - disposal of solid waste
B21 - mechanical metal-working without essentially removing material
B22 - casting
B23 - machine tools
B24 - grinding
B25 - hand tools
B26 - hand cutting tools
B27 - working or preserving wood or similar material
B28 - working cement, clay, or stone
B29 - working of plastics
B30 - presses
B31 - making articles of paper, cardboard or material worked in a manner analogous to paper
B32 - layered products
B33 - additive manufacturing technology
B41 - printing
B42 - bookbinding
B43 - writing or drawing implements
B44 - decorative arts
B60 - vehicles in general
B61 - railways
B62 - land vehicles for travelling otherwise than on rails
B63 - ships or other waterborne vessels
B64 - aircraft
B65 - conveying
B66 - hoisting
B67 - opening, closing {or cleaning} bottles, jars or similar containers
B68 - saddlery
B81 - microstructural technology
B82 - nanotechnology
B99 - subject matter not otherwise provided for in this section
C - chemistry
C01 - inorganic chemistry
C02 - treatment of water, waste water, sewage, or sludge
C03 - glass
C04 - cements
C05 - fertilisers
C06 - explosives
C07 - organic chemistry
C08 - organic macromolecular compounds
C09 - dyes
C10 - petroleum, gas or coke industries
C11 - animal or vegetable oils, fats, fatty substances or waxes
C12 - biochemistry
C13 - sugar industry
C14 - skins
C21 - metallurgy of iron
C22 - metallurgy
C23 - coating metallic material
C25 - electrolytic or electrophoretic processes
C30 - crystal growth
C40 - combinatorial technology
C99 - subject matter not otherwise provided for in this section
D - textiles
D01 - natural or man-made threads or fibres
D02 - yarns
D03 - weaving
D04 - braiding
D05 - sewing
D06 - treatment of textiles or the like
D07 - ropes
D10 - indexing scheme associated with sublasses of section d, relating to textiles
D21 - paper-making
D99 - subject matter not otherwise provided for in this section
E - fixed constructions
E01 - construction of roads, railways, or bridges
E02 - hydraulic engineering
E03 - water supply
E04 - building
E05 - locks
E06 - doors, windows, shutters, or roller blinds in general
E21 - earth drilling
E99 - subject matter not otherwise provided for in this section
F - mechanical engineering
F01 - machines or engines in general
F02 - combustion engines
F03 - machines or engines for liquids
F04 - positive - displacement machines for liquids
F05 - indexing schemes relating to engines or pumps in various subclasses of classes f01-f04
F15 - fluid-pressure actuators
F16 - engineering elements and units
F17 - storing or distributing gases or liquids
F21 - lighting
F22 - steam generation
F23 - combustion apparatus
F24 - heating
F25 - refrigeration or cooling
F26 - drying
F27 - furnaces
F28 - heat exchange in general
F41 - weapons
F42 - ammunition
F99 - subject matter not otherwise provided for in this section
G - physics
G01 - measuring
G02 - optics
G03 - photography
G04 - horology
G05 - controlling
G06 - computing
G07 - checking-devices
G08 - signalling
G09 - education
G10 - musical instruments
G11 - information storage
G12 - instrument details
G16 - information and communication technology [ict] specially adapted for specific application fields
G21 - nuclear physics
G99 - subject matter not otherwise provided for in this section
H - electricity
H01 - basic electric elements
H02 - generation
H03 - basic electronic circuitry
H04 - electric communication technique
H05 - electric techniques not otherwise provided for
H99 - subject matter not otherwise provided for in this section
Y - new / cross sectional technologies
Y02 - technologies or applications for mitigation or adaptation against climate change
Y04 - information or communication technologies having an impact on other technology areas
Y10 - technical subjects covered by former uspc

More Options ...

Title: Methods and systems for 3D printing with powders

Abstract

A method of printing a three dimensional article (201) can include forming a bottom layer of the three dimensional article (201) by spraying a dry build material powder (210) onto a build platform (230) while heating the dry build material powder (210). The dry build material powder (210) can include metal or ceramic particles mixed with a polymeric binder having a softening point temperature. The dry build material powder (210) can be heated to a temperature above the softening point temperature such that the dry build material powder (210) adheres to the build platform (230). Subsequent layers can be formed by spraying dry build material powder (210) onto a lower layer while heating the dry build material powder (210) such that the dry build material powder (210) adheres to the lower layer.

Inventors:: Fang, Zhigang Zak; Sun, Pei

Issue Date:: 2021-12-14

Research Org.:: Univ. of Utah, Salt Lake City, UT (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1860160

Patent Number(s):: 11198177

Application Number:: 16/644,928

Assignee:: University of Utah Research Foundation (Salt Lake City, UT)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B05 - SPRAYING OR ATOMISING IN GENERAL B05B - SPRAYING APPARATUS

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER

Show more

B - PERFORMING OPERATIONS B05 - SPRAYING OR ATOMISING IN GENERAL B05B - SPRAYING APPARATUS
B05B7/1404 - {Arrangements for supplying particulate material}
B05B7/1486 - {for spraying particulate material in dry state}
B05B7/168 - {with means for heating or cooling after mixing

B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F2201/02 - Nitrogen
B22F2201/11 - Argon
B22F2201/50 - air
B22F3/1028 - {Controlled cooling}
B22F3/115 - by spraying molten metal, i.e. spray sintering, spray casting

B - PERFORMING OPERATIONS B28 - WORKING CEMENT, CLAY, OR STONE B28B - SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
B28B1/001 - {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS
B29C64/159 - using only gaseous substances, e.g. vapour deposition
B29C64/209 - Heads

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
B33Y10/00 - Processes of additive manufacturing
B33Y30/00 - Apparatus for additive manufacturing

C - CHEMISTRY C08 - ORGANIC MACROMOLECULAR COMPOUNDS C08K - Use of inorganic or non-macromolecular organic substances as compounding ingredients
C08K2003/0812 - {Aluminium}
C08K2003/0843 - {Cobalt}
C08K2003/0856 - {Iron}
C08K2003/0862 - {Nickel}
C08K2003/0881 - {Titanium}
C08K2003/0887 - {Tungsten}
C08K2003/222 - {Magnesia, i.e. magnesium oxide}
C08K2003/2227 - {of aluminium}
C08K2003/2244 - {of zirconium}
C08K2003/282 - {Binary compounds of nitrogen with aluminium}
C08K3/013 - Fillers, pigments or reinforcing additives
C08K3/08 - Metals
C08K3/14 - Carbides
C08K3/22 - of metals
C08K3/28 - Nitrogen-containing compounds
C08K3/36 - Silica
C08K3/38 - Boron-containing compounds
C08K7/00 - Use of ingredients characterised by shape

C - CHEMISTRY C08 - ORGANIC MACROMOLECULAR COMPOUNDS C08L - COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
C08L101/12 - characterised by physical features, e.g. anisotropy, viscosity or electrical conductivity

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
Y02P10/25 - by increasing the energy efficiency of the process

Show less

DOE Contract Number:: AR0000420

Resource Type:: Patent

Resource Relation:: Patent File Date: 09/05/2018

Country of Publication:: United States

Language:: English

Citation Formats


                    Fang, Zhigang Zak, and Sun, Pei. Methods and systems for 3D printing with powders.  United States: N. p., 2021. 
        Web.

Copy to clipboard


                    Fang, Zhigang Zak, & Sun, Pei. Methods and systems for 3D printing with powders.  United States.

Copy to clipboard


                    Fang, Zhigang Zak, and Sun, Pei. Tue .  
        "Methods and systems for 3D printing with powders".  United States.  https://www.osti.gov/servlets/purl/1860160.

Copy to clipboard


                    
@article{osti_1860160,

  title        = {Methods and systems for 3D printing with powders},

  author       = {Fang, Zhigang Zak and Sun, Pei},

  abstractNote = {A method of printing a three dimensional article (201) can include forming a bottom layer of the three dimensional article (201) by spraying a dry build material powder (210) onto a build platform (230) while heating the dry build material powder (210). The dry build material powder (210) can include metal or ceramic particles mixed with a polymeric binder having a softening point temperature. The dry build material powder (210) can be heated to a temperature above the softening point temperature such that the dry build material powder (210) adheres to the build platform (230). Subsequent layers can be formed by spraying dry build material powder (210) onto a lower layer while heating the dry build material powder (210) such that the dry build material powder (210) adheres to the lower layer.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2021},

  month        = {12}

}

Copy to clipboard

Patent:

Save / Share:

Export Metadata

Save to My Library

Works referenced in this record:

The effects of two gas flow streams with initial temperature and pressure differences in cold spraying nozzle
journal, February 2014

Tang, Wenyong; Liu, Juanfang; Chen, Qinghua
Surface and Coatings Technology, Vol. 240
https://doi.org/10.1016/j.surfcoat.2013.12.019

Powder and binder systems for use in metal and ceramic powder injection molding
patent, December 1999

Yang, Xiaoming; Petcavich, Robert J.
US Patent Document 6,008,281
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/6008281

Additive Manufacturing of Ceramic Turbine Components by Transient Liquid Phase Bonding Using Metal or Ceramic Binders
patent-application, March 2016

Mironets, Sergey; Cook III, Grant O.
US Patent Application 14/786919; 20160083303
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20160083303

Methods for fabricating three-dimensional metallic objects via additive manufacturing using metal oxide pastes
patent, May 2016

Shah, Ramille N.; Jakus, Adam E.; Dunand, David C.
US Patent Document 9,327,448
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/9327448

Powder coating composition
patent-application, May 2004

Nakano, Hiroshi
US Patent Application 10/606017; 20040102561
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20040102561

System for Fabricating and Interface Layer to Separate Binder Jetted Objects from Support Structures
patent-application, October 2017

Myerberg, Jonah Samuel; Gibson, Michael Andrew; Sachs, Emmanuel Michael
US Patent Application 15/469403; 20170297106
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20170297106

Laser Additive Manufacture of Three-Dimensional Components Containing Multiple Materials Formed as Integrated Systems
patent-application, February 2015

Subramanian, Ramesh; Kamel, Ahmed; Bruck, Gerald J.
US Patent Application 14/513535; 20150034604
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20150034604

Additive Manufacturing of Metal Matrix Composite Feestock
patent-application, November 2016

Nardi, Aaron T.; Dardas, Zissis; Beals, James T.
US Patent Application 15/112042; 20160339518
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20160339518

Method of making a ceramic body of densified tungsten carbide
patent-application, May 2003

Anderson, Linwood
US Patent Application 10/008806; 20030084752
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20030084752

Methods for composite filament fabrication in three dimensional printing
patent, September 2015

Mark, Gregory Thomas; Gozdz, Antoni S.
US Patent Document 9,126,365
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/9126365

Surface modified particulate and sintered or injection molded products
patent, December 2016

Heikkila, Kurt E.
US Patent Document 9,512,544
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/9512544

Functional Inorganic and Ceramic Additive Manufacturing
patent-application, April 2016

Schmidt, Wayde R.
US Patent Application 14/882951; 20160107331
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20160107331

Plasma-transferred-arc torch construction
patent, June 1983

Rotolico, Anthony J.; Romero, Eduardo
US Patent Document 4,389,559
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/4389559

Production of substantially spherical metal powders
patent, August 2016

Fang, Zhigang; Xia, Yang; Sun, Pei
US Patent Document 9,421,612
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/9421612

Copolyesters containing 2,2',6,6'-tetramethylbiphenyl-4,4'-dicarboxylate moieties
patent, July 1977

Paschke, Edward E.
US Patent Document 4,035,342
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/4035342

Metallic filled pastes
patent, October 2003

Moussa, Khalil; Newell, Kenneth; Hinczewski, Catherine
US Patent Document 6,630,009
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/6630009

Process for forming integrated structures using three dimensional printing techniques
patent, April 2002

Johnson, Jr., David W.; Kochanski, Gregory Peter; Lanzerotti, Louis J.
US Patent Document 6,363,606
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/6363606

Acicular Metal Particles Having a High Aspect Ratio and Non-Catalytic Methods for Making the Same
patent-application, August 2011

Aravinda, Chitradurga L. Rao
US Patent Application 13/122719; 20110195264
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20110195264

Method of spray forming readily weldable and machinable metal deposits
patent-application, September 2001

Kinane, Jeffrey Alan; Collins, David Robert; Zaluzec, Matthew John
US Patent Application 09/875847; 20010023754
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20010023754

Metal powder composition for laser sintering
patent, November 2004

Geving, Brad; Schmidt, Kris; Newell, Kenneth
US Patent Document 6,814,926
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/6814926

Coated powder particles for producing three-dimensional bodies by means of a layer constituting method
patent, May 2010

Pfeifer, Rolf; Shen, Jialin
US Patent Document 7,722,802
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/7722802

Similar Records in DOE Patents and OSTI.GOV collections:

System and method for forming activated carbon aerogels and performing 3D printing

Patent Chandrasekaran, Swetha; Baumann, Theodore F.; Worsley, Marcus A.

Making a carbon aerogel involves 3-D printing an ink to make a printed part, removing the solvent from the printed part, and carbonizing the printed part (with the solvent removed) to make the aerogel. The ink is based on a solution of a resorcinol-formaldehyde resin (RF resin), water, and an organic thickener. Advantageously, the RF resin contains an acid catalyst, which tends to produce carbon aerogels with higher surface areas upon activation than those produced from methods involving an ink composition containing a base catalyzed resin.
Full Text Available
System and method for 3D printing of aerogels

Patent Worsley, Marcus A.; Duoss, Eric; Kuntz, Joshua; ...

A method of forming an aerogel. The method may involve providing a graphene oxide powder and mixing the graphene oxide powder with a solution to form an ink. A 3D printing technique may be used to write the ink into a catalytic solution that is contained in a fluid containment member to form a wet part. The wet part may then be cured in a sealed container for a predetermined period of time at a predetermined temperature. The cured wet part may then be dried to form a finished aerogel part.
Full Text Available
Systems and methods for automated nozzle design and 3D printing

Patent Lewis, Jennifer A.; Skylar-Scott, Mark Andrew; Mueller, Jochen; ...

A present disclosure relates to a system for automatic design and manufacturing of 3D printing units and 3D products. The system is configured to obtain specification of a target structure corresponding to a 3D product; automatically determine a design and a printing path of a 3D printing unit based on the specification of the target structure, wherein the 3D printing unit is a micronozzle unit configured to print the target structure of the 3D product; automatically determine a manufacturing procedure to print the 3D printing unit based on the specification of the target structure; and instruct a 3D printer tomore » « less
Full Text Available
System and method for integrated absorber intercooling via rich solvent stream using 3D-printed active packings

Patent Moore, Thomas Charles Reading; Stolaroff, Joshuah K.

The present disclosure relates to an absorber column apparatus for removing a selected component of a gas. The apparatus may have a first zone, a second zone and a third zone, wherein the first and third zones form a first domain through which a first fluid laden with a select gaseous component to be removed therefrom flows along concurrently with a second fluid. The second fluid at least substantially removes the select gaseous component from the first fluid to create a third fluid. The first fluid leaves the absorber column as a fourth fluid with the select gaseous component atmore » « less
Full Text Available
3D printed modular centrifugal contactors and method for separating moieties using 3D printed optimized surfaces

Patent Wardle, Kent E.

The present invention provides an annular centrifugal contactor, having a housing to receive a plurality of liquids; a rotor inside the housing; an annular mixing zone, with a plurality of fluid retention reservoirs; and an adjustable stem that can be raised to restrict the flow of a liquid into the rotor or lowered to increase the flow of liquid into the rotor. The invention also provides a method for transferring moieties from a first liquid to a second liquid, the method having the steps of combining the fluids in a housing whose interior has helically shaped first channels; subjecting themore » « less
Full Text Available

Similar Records

Title: Methods and systems for 3D printing with powders

Abstract

Citation Formats

The effects of two gas flow streams with initial temperature and pressure differences in cold spraying nozzle journal, February 2014

Powder and binder systems for use in metal and ceramic powder injection molding patent, December 1999

Additive Manufacturing of Ceramic Turbine Components by Transient Liquid Phase Bonding Using Metal or Ceramic Binders patent-application, March 2016

Methods for fabricating three-dimensional metallic objects via additive manufacturing using metal oxide pastes patent, May 2016

Powder coating composition patent-application, May 2004

System for Fabricating and Interface Layer to Separate Binder Jetted Objects from Support Structures patent-application, October 2017

Laser Additive Manufacture of Three-Dimensional Components Containing Multiple Materials Formed as Integrated Systems patent-application, February 2015

Additive Manufacturing of Metal Matrix Composite Feestock patent-application, November 2016

Method of making a ceramic body of densified tungsten carbide patent-application, May 2003

Methods for composite filament fabrication in three dimensional printing patent, September 2015

Surface modified particulate and sintered or injection molded products patent, December 2016

Functional Inorganic and Ceramic Additive Manufacturing patent-application, April 2016

Plasma-transferred-arc torch construction patent, June 1983

Production of substantially spherical metal powders patent, August 2016

Copolyesters containing 2,2',6,6'-tetramethylbiphenyl-4,4'-dicarboxylate moieties patent, July 1977

Metallic filled pastes patent, October 2003

Process for forming integrated structures using three dimensional printing techniques patent, April 2002

Acicular Metal Particles Having a High Aspect Ratio and Non-Catalytic Methods for Making the Same patent-application, August 2011

Method of spray forming readily weldable and machinable metal deposits patent-application, September 2001

Metal powder composition for laser sintering patent, November 2004

Coated powder particles for producing three-dimensional bodies by means of a layer constituting method patent, May 2010

The effects of two gas flow streams with initial temperature and pressure differences in cold spraying nozzle
journal, February 2014

Powder and binder systems for use in metal and ceramic powder injection molding
patent, December 1999

Additive Manufacturing of Ceramic Turbine Components by Transient Liquid Phase Bonding Using Metal or Ceramic Binders
patent-application, March 2016

Methods for fabricating three-dimensional metallic objects via additive manufacturing using metal oxide pastes
patent, May 2016

Powder coating composition
patent-application, May 2004

System for Fabricating and Interface Layer to Separate Binder Jetted Objects from Support Structures
patent-application, October 2017

Laser Additive Manufacture of Three-Dimensional Components Containing Multiple Materials Formed as Integrated Systems
patent-application, February 2015

Additive Manufacturing of Metal Matrix Composite Feestock
patent-application, November 2016

Method of making a ceramic body of densified tungsten carbide
patent-application, May 2003

Methods for composite filament fabrication in three dimensional printing
patent, September 2015

Surface modified particulate and sintered or injection molded products
patent, December 2016

Functional Inorganic and Ceramic Additive Manufacturing
patent-application, April 2016

Plasma-transferred-arc torch construction
patent, June 1983

Production of substantially spherical metal powders
patent, August 2016

Copolyesters containing 2,2',6,6'-tetramethylbiphenyl-4,4'-dicarboxylate moieties
patent, July 1977

Metallic filled pastes
patent, October 2003

Process for forming integrated structures using three dimensional printing techniques
patent, April 2002

Acicular Metal Particles Having a High Aspect Ratio and Non-Catalytic Methods for Making the Same
patent-application, August 2011

Method of spray forming readily weldable and machinable metal deposits
patent-application, September 2001

Metal powder composition for laser sintering
patent, November 2004

Coated powder particles for producing three-dimensional bodies by means of a layer constituting method
patent, May 2010