# US 12,179,264 B2 · Object producing method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,179,264 B2 - Document ID: US12179264B2 - Status: Granted - Kind: B2 - Application number: 17/654,587 - Filed: 2022-03-12 - Published: 2022-09-29 - Granted: 2024-12-31 - Earliest claimed: 2021-03-22 - Assignees: Ricoh Company, Ltd. - Applicants: Shinichiroh Satoh; Naoki Oya - Inventors: Shinichiroh Satoh; Naoki Oya - Web page: https://patentgrep.com/patent/US12179264B2 ## CPC - B22F 10/14: by jetting of binder onto a bed of metal powder - B22F 10/64: by thermal means (control of energy beam parameters for post heating B22F10/364) - 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 - B33Y 10/00: Processes of additive manufacturing - B33Y 40/20: Post-treatment, e.g. curing, coating or polishing - B22F 2301/052: Aluminium - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B29K 2029/00: Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals {or derivatives thereof} as moulding material - B29K 2505/02: Aluminium - 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 - 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) - 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 - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract Provided is an object producing method including a powder layer forming step of forming a layer of a powder containing sinterable particles, an object forming liquid applying step of applying an object forming liquid to the layer of the powder to form an object forming region, and a sintering inhibiting liquid applying step of applying a sintering inhibiting liquid to the layer of the powder to form a sintering inhibited region in which sintering of the particles is inhibited, and includes a layer laminating step of sequentially repeating these steps to form a laminate. The object forming region and the sintering inhibited region adjoin each other. The sintering inhibiting liquid contains a first resin. The sintering inhibited region contains the first resin or a second resin derived from the first resin. A predicted amount of a residue calculated by a predetermined method is 800 ppm or greater. ## Claims ### Claim 1 An object producing method, comprising: forming a layer of a powder containing particles that are sinterable; applying an object forming liquid to the layer of the powder to form an object forming region; and applying a sintering inhibiting liquid to the layer of the powder to form a sintering inhibited region in which sintering of the particles is inhibited, wherein the object producing method further comprises sequentially repeating the forming, the applying the object forming liquid, and the applying the sintering inhibiting liquid, to form a laminate, the object forming region and the sintering inhibited region adjoin each other, the sintering inhibiting liquid contains a first resin, all compounds in the sintering inhibiting liquid are dissolved, the sintering inhibited region contains the first resin or a second resin derived from the first resin, and a predicted amount of a residue calculated by multiplying a mass ratio (mass of the first resin or the second resin/mass of the powder) between a mass of the first resin or the second resin and a mass of the powder in a sintering inhibited part formed by laminating the sintering inhibited region by a ratio of a residue of the first resin or the second resin through thermal decomposition at 550 degrees C. is 800 ppm or greater. ### Claim 2 (depends on 1) The object producing method according to claim 1, wherein the predicted amount of the residue is 1,000 ppm or greater. ### Claim 3 (depends on 1) The object producing method according to claim 1, wherein the ratio of the residue of the first resin or the second resin in the sintering inhibited part through thermal decomposition at 550 degrees C. is 0.100 or higher. ### Claim 4 (depends on 1) The object producing method according to claim 1, wherein a viscosity of the sintering inhibiting liquid at 25 degrees C. is 30 mPa·s or lower. ### Claim 5 (depends on 1) The object producing method according to claim 1, wherein the sintering inhibited region contains the second resin, and the ratio of the residue of the second resin in the sintering inhibited part through thermal decomposition at 550 degrees C. is higher than a ratio of a residue of the first resin through thermal decomposition at 550 degrees C. ### Claim 6 (depends on 1) The object producing method according to claim 1, wherein the sintering inhibited region contains the second resin, and the second resin in the sintering inhibited part is produced through a cross-linking reaction of the first resin. ### Claim 7 (depends on 1) The object producing method according to claim 1, wherein the first resin is polyvinyl pyrrolidone. ### Claim 8 (depends on 1) The object producing method according to claim 1, wherein the first resin is at least one selected from the group consisting of polyvinyl chloride, poly vinylidene chloride, cellulose acetate, polyacrylonitrile, acrylonitrile-styrene copolymers, acrylonitrile-butadiene-styrene copolymers, vinyl chloride-vinyl acetate copolymers, polyethylene terephthalate, phenol resins, melamine resins, urea resins, unsaturated polyester, epoxy resins, silicon resins, polyvinyl polypyrrolidone, and benzoguanamine resins. ### Claim 9 (depends on 1) The object producing method according to claim 1, wherein the particles contain aluminum. ### Claim 10 (depends on 1) The object producing method according to claim 1, wherein a relative sintering density of a sintered product formed by sintering the sintering inhibited part formed by laminating the sintering inhibited region is 60% or lower. ### Claim 11 (depends on 1) The object producing method according to claim 1, wherein in the applying the object forming liquid, the object forming liquid is applied to the layer of the powder to form the object forming region and a support region, and the object forming region and the support region adjoin each other via the sintering inhibited region. ### Claim 12 (depends on 1) The object producing method according to claim 1, wherein an amount of application of the sintering inhibiting liquid applied per unit area of the sintering inhibited region is higher than an amount of application of the object forming liquid applied per unit area of the object forming region. ### Claim 13 (depends on 1) The object producing method according to claim 1, wherein in the applying the object forming liquid, the object forming liquid is further applied to the sintering inhibited region after the sintering inhibited region is formed. ### Claim 14 (depends on 1) The object producing method according to claim 1, wherein the object forming region is surrounded by the sintering inhibited region. ### Claim 15 (depends on 1) The object producing method according to claim 1, wherein at a boundary between the object forming region and the sintering inhibited region, the sintering inhibiting liquid is applied within 100 msec from when the object forming liquid is applied. ### Claim 16 (depends on 1) The object producing method according to claim 1, wherein the laminate includes a plurality of object forming parts each formed by laminating the object forming region, and a coupling part coupling the object forming parts to each other, and at least regions of the coupling part contacting the object forming parts are formed of sintering inhibited parts each formed by laminating the sintering inhibited region. ### Claim 17 (depends on 1) The object producing method according to claim 1, wherein the laminate includes an object forming part formed by laminating the object forming region, and a sintering inhibited part formed by laminating the sintering inhibited region, and a whole circumference of the object forming part is covered by the sintering inhibited part. ### Claim 18 (depends on 1) The object producing method according to claim 1, further comprising sintering the object at a sintering temperature of 600 degrees C. or lower, wherein the sintering inhibiting liquid contains 10% by mass or less water relative to the mass of the sintering inhibiting liquid, and wherein the particles comprise aluminum. ### Claim 19 (depends on 1) The object producing method according to claim 1, wherein the sintering inhibited region contains the first resin and the second resin derived from the first resin, and wherein the second resin is chemically different from the first resin.