# US 12,005,641 B2 · Green body including a metal nanoparticle binder

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- Number: US 12,005,641 B2
- Document ID: US12005641B2
- Status: Granted
- Kind: B2
- Application number: 17/857,362
- Filed: 2022-07-05
- Published: 2022-10-20
- Granted: 2024-06-11
- Earliest claimed: 2022-07-05
- Assignees: Hewlett-Packard Development Company, L.P.
- Applicants: Hewlett-Packard Development Company, L.P.
- Inventors: Kristopher J. Erickson; Thomas C. Anthony
- Web page: https://patentgrep.com/patent/US12005641B2

## CPC

- B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
- B22F 1/054: Nanosized particles
- B22F 10/14: by jetting of binder onto a bed of metal powder
- B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C04B 35/111: Fine ceramics
- C04B 35/14: based on silica
- C04B 35/46: based on titanium oxides or titanates (containing also zirconium or hafnium oxides, zirconates or hafnates C04B35/49)
- C04B 35/486: Fine ceramics
- C04B 35/565: based on silicon carbide
- C04B 35/587: Fine ceramics
- C04B 35/622: Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B 35/62218: {obtaining ceramic films, e.g. by using temporary supports}
- C04B 35/634: Polymers (C04B35/636 takes precedence)
- C04B 35/64: Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F})
- B22F 2304/05: Submicron size particles
- B22F 2998/10: Processes characterised by the sequence of their steps
- C04B 2235/3206: Magnesium oxides or oxide-forming salts thereof
- C04B 2235/3215: Barium oxides or oxide-forming salts thereof
- C04B 2235/3217: Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
- C04B 2235/3218: Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol
- C04B 2235/3225: Yttrium oxide or oxide-forming salts thereof
- C04B 2235/3232: Titanium oxides or titanates, e.g. rutile or anatase
- C04B 2235/3244: Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
- C04B 2235/3272: Iron oxides or oxide forming salts thereof, e.g. hematite, magnetite
- C04B 2235/3284: Zinc oxides, zincates, cadmium oxides, cadmiates, mercury oxides, mercurates or oxide forming salts thereof
- C04B 2235/3286: Gallium oxides, gallates, indium oxides, indates, thallium oxides, thallates or oxide forming salts thereof, e.g. zinc gallate
- C04B 2235/3293: Tin oxides, stannates or oxide forming salts thereof, e.g. indium tin oxide [ITO]
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/3826: Silicon carbides
- C04B 2235/3847: Tungsten carbides
- C04B 2235/3865: Aluminium nitrides
- C04B 2235/3873: Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
- C04B 2235/422: Carbon
- C04B 2235/442: Carbonates
- C04B 2235/5445: submicron sized, i.e. from 0,1 to 1 micron
- C04B 2235/5454: nanometer sized, i.e. below 100 nm
- C04B 2235/6026: Computer aided shaping, e.g. rapid prototyping
- C04B 2235/667: Sintering using wave energy, e.g. microwave sintering
- C04B 2235/96: Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
- Y02P 10/25: Process efficiency
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

According to an example, a green body may include from about 1 wt. % to about 20 wt. % of a metal nanoparticle binder and a build material powder, wherein the metal nanoparticle binder is selectively located within an area of the green body to impart a strength greater than about 3 MPa.

## Claims

### Claim 1

A method, comprising:
spreading a layer of a metal or metal alloy build material powder;
selectively depositing from about 1 wt. % to about 20 wt. % of a metal nanoparticle binder onto the layer of the metal or metal alloy build material powder; and
applying energy to form a green body from the layer of the metal or metal alloy build material powder and the metal nanoparticle binder deposited on the layer of the metal or metal alloy build material powder,
wherein the metal nanoparticle binder is selectively located within a first area of the green body to impart a strength greater than about 3 MPa in the first area.

### Claim 2 (depends on 1)

The method of claim 1, further comprising selectively applying a polymer binder to the layer of the metal or metal alloy build material powder.

### Claim 3 (depends on 1)

The method of claim 1, wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a bridge.

### Claim 4 (depends on 1)

The method of claim 1, wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a cantilever.

### Claim 5 (depends on 1)

The method of claim 1, wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a wall with thickness at or below a threshold.

### Claim 6 (depends on 1)

The method of claim 1, wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including an exterior corner or edge.

### Claim 7 (depends on 1)

The method of claim 1, wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a middle section of a high aspect ratio part.

### Claim 8 (depends on 1)

The method of claim 1, wherein selectively depositing the metal nanoparticle binder further comprises selecting the first area based on the first area including a junction between adjacent parts of the green body.

### Claim 9

A method, comprising:
spreading a layer of a build material powder;
selectively depositing a first agent including from about 1 wt. % to about 20 wt. % of a metal nanoparticle binder onto the layer of the build material powder;
selectively depositing a second agent including a polymer binder onto the layer of the build material powder, wherein the polymer binder is selected from the group consisting of polypropylene, polyethylene, low density polyethylene, high density polyethylene, polyethylene oxide, polyethylene glycol, polystyrene, polyphenyl ether, polyamide 11, polyamide 12, polymethyl pentene, polyoxymethylene, polyethylene terephthalate, polybutylene terephthalate, polyvinylidene fluoride, polytetrafluoroethylene, perfluoroalkoxy alkane, polyphenylene sulfide, and polyether ether ketone; and
applying energy to form a green body from the layer of build material powder and the first and second agents deposited on the layer of the build material powder,
wherein the first agent including the metal nanoparticle binder is selectively located within a first area of the green body to impart a strength greater than about 3 MPa in the first area.

### Claim 10 (depends on 1)

The method of claim 1, wherein the metal nanoparticle binder is selected from the group consisting of AlN, SiC, Si3N4, WC, Al2O3, Al(OH)3, Fe2O3, Fe3O4, MgO, SiO2, TiO2, Y2O3, ZnO, ZrO2, BaCO3, In2O3, SnO2, carbon, magnesium, manganese, aluminum, iron, titanium, niobium, tungsten, chromium, tantalum, cobalt, nickel, vanadium, zirconium, molybdenum, palladium, platinum, copper, silver, gold, cadmium, zinc, and combinations thereof.

### Claim 11 (depends on 1)

The method of claim 1, wherein the metal nanoparticle binder is present in an amount ranging from about 1 wt. % to about 15 wt. %.

### Claim 12 (depends on 1)

The method of claim 1, wherein the first area of the green body has a predicted internal stress that exceeds about 1 MPa based upon analysis of the green body.

### Claim 13 (depends on 1)

The method of claim 1, wherein the metal present in the metal nanoparticle binder is the same as a metal in the metal material powder.

### Claim 14 (depends on 2)

The method of claim 2, wherein the selectively depositing includes selectively depositing an agent including the metal nanoparticle binder and the polymer binder.

### Claim 15 (depends on 1)

The method of claim 1, wherein the metal nanoparticle binder is present in an amount ranging from about 1 wt. % to about 5 wt. %.