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Powder for rapid prototyping and associated production method

A technology of powder and micro-powder, which is applied in the direction of manufacturing tools, additive manufacturing, additive processing, etc., and can solve the problems of material becoming brittle and unable to increase tensile strength

Active Publication Date: 2012-01-25
EOS ELECTRO OPTICAL SYST
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Although the material can be strengthened (increased E modulus), the tensile strength cannot be significantly improved, and the achievable improvement must be paid for by making the material brittle

Method used

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  • Powder for rapid prototyping and associated production method
  • Powder for rapid prototyping and associated production method
  • Powder for rapid prototyping and associated production method

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0049] The powder contains a first matrix in the form of substantially spherical powder particles (18) formed of an aromatic polyetherketone, especially polyaryletherketone (PEEK) plastic, which has an oxygen of the formula Base-1,4-phenylene-oxy-1,4-phenylene-carbonyl-1,4-phenylene repeat unit:

[0050]

[0051] This material is commercially available, for example, from the company Victrex Plc. under the trade name "PEEK". The material properties are: tensile strength over 90 MPa, E modulus in the range over 3.5 GPa (according to ISO527). Furthermore, the material is distinguished by an extremely good temperature stability, so that molded parts made from it can also be used in areas with very high thermal requirements.

[0052] Powder particles are preferably produced from this material according to one of the following methods:

[0053] 1. Spray drying

[0054] 2. Grinding, and

[0055] 3. Melt spray or granulation

[0056] spray drying

[0057] For this, as ima...

Embodiment 2

[0074] Such as Figure 4 As shown, the powder comprises a first portion formed of a matrix material in the form of substantially spherical powder particles 118 and at least one other portion in the form of reinforcing and / or reinforcing fibers 140 . The base portion may be formed from metal or thermoplastic.

[0075] Implement the following examples:

[0076] The PA12 powder had a particle size distribution of d50 about 50 microns and was mixed with 10 volume % of two different types of carbon fibers with an average fiber length L50 of about 70 microns and a fiber thickness of 7 microns. The powder thus obtained can be processed on commercially available rapid prototyping machines to form defect-free shaped bodies.

[0077] The mechanical properties of samples produced according to the layered manufacturing method based on this powder / fiber mixture can be significantly improved compared to structural components without fibres. Specifically, the E modulus was increased to ov...

Embodiment 3

[0081] According to a third embodiment, such as image 3 As shown, a powder with a significantly higher fiber content, ie more than 30% by volume, is produced, but can be used in a layered manufacturing process due to its good flowability.

[0082] It is characterized in that the fibers 240 are embedded in the substantially spherical powder compact 218 to form the matrix material of the structural part to be manufactured, preferably the fibers are substantially completely surrounded by the matrix material, such as Figure 5 shown.

[0083] To manufacture this powder, minor modifications of the aforementioned methods, namely spray drying, grinding, granulation and melt spraying, can be considered:

[0084] spray drying

[0085] The method as Figure 6 shown. its with image 3 The preceding methods shown differ only in the liquid phase, for example reinforcing or reinforcing fibers 340 are stirred into ethanol or an ethanol / water mixture 320 in addition to the matrix micr...

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Abstract

The invention relates to powders for use in the production of three-dimensional structures or moulded bodies, using layered manufacturing methods and to methods for the economical production of said structures or bodies. Characteristic features of the powders are that they have an excellent flow behaviour and that they enable the moulded body that is produced using the powder in the rapid prototyping process to exhibit significantly improved mechanical or thermal characteristics. According to one particularly advantageous embodiment the powder comprises a first fraction, which is present in the form of essentially spherical powder particles and is formed by a matrix material, and at least one other fraction in the form of strengthening and / or reinforcing fibres, which are preferably embedded in the matrix material.

Description

technical field [0001] In general, the invention relates to a method for the manufacture of spatial, especially spatially composite structures or shaped bodies, which is carried out using layered manufacturing methods, such as the known "rapid prototyping methods based on powder production" or "free-body Modeling Method (SFF)". These powder-based rapid prototyping methods are known, for example, 3D laser sintering, 3D laser melting or 3D printing. [0002] In particular, the present invention relates to powders for use in these methods, and methods for the economical manufacture of such powders. Background technique [0003] The currently known automatic methods for producing shaped bodies of composite structures, usually with computer-controlled addition, are carried out by pouring from powdered material, which is layer-by-layer at specific locations or areas Heating is applied so that a melting process or a sintering process takes place. The heating is usually carried o...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): C08J3/12C08G65/40C08G67/00C08J3/20
CPCC08J3/203B29C67/0051B29K2105/16B29B9/14C08J3/12C08J2329/12B29B13/10C08J2371/12B29B13/007B33Y10/00B29B2009/125B29C64/314B33Y40/10B33Y70/10
Inventor 彼得·黑塞蒂尔曼·保罗理查德·韦斯
Owner EOS ELECTRO OPTICAL SYST