WO2020148914A1 - Procédé de traitement thermique de matériau pulvérulent, procédé de fusion sur lit de poudre, et objets produits par ces procédés - Google Patents
Procédé de traitement thermique de matériau pulvérulent, procédé de fusion sur lit de poudre, et objets produits par ces procédés Download PDFInfo
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- WO2020148914A1 WO2020148914A1 PCT/JP2019/001567 JP2019001567W WO2020148914A1 WO 2020148914 A1 WO2020148914 A1 WO 2020148914A1 JP 2019001567 W JP2019001567 W JP 2019001567W WO 2020148914 A1 WO2020148914 A1 WO 2020148914A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B13/00—Conditioning or physical treatment of the material to be shaped
- B29B13/02—Conditioning or physical treatment of the material to be shaped by heating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C64/00—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
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C64/00—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
- B29C64/30—Auxiliary operations or equipment
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/314—Preparation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B33Y70/00—Materials specially adapted for additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- B33Y80/00—Products made by additive manufacturing
Definitions
- the present invention relates to a heat treatment method for powder materials, a powder bed fusion bonding method, and products manufactured by these methods.
- the thin layer of the powder material formed in the thin layer forming container is preheated to a temperature lower than the softening point of the powder material by a heater or the like before irradiation with laser light. This is because the irradiation of the laser beam raises the temperature of the powder material to the melting temperature in a short time and reduces the temperature difference between the melting portion and its peripheral portion.
- Patent Documents 1 and 2 describe such a powder bed fusion bonding method.
- the disclosed embodiment was created in view of the above-mentioned problems, and heat treatment of a powder material capable of suppressing aggregation of particles of the powder material when forming a thin layer of the powder material.
- Methods and powder bed fusion bonding methods are provided, as well as powder materials and shaped articles obtained using these methods.
- a temperature at which the resin powder does not soften a temperature at which the aggregation of the resin powder is suppressed, and a time required to inhibit the aggregation of the resin powder.
- the resin powder is a temperature at which the resin powder does not soften, a temperature at which aggregation of the resin powder is suppressed, and a time required to inhibit aggregation of the resin powder, A step of heat-treating the powder, moving the carrying member on the upper surface of the container, leveling the surface of the container while carrying the resin powder into the container, forming a thin layer of the resin powder, and based on slice data And a step of irradiating the thin layer with an energy beam to form a solidified layer. Further, according to another aspect of the embodiment, there is provided a powder material and a shaped article obtained by carrying out the above method.
- the resin powder is heat-treated at a temperature at which the resin powder does not soften and at a temperature at which the aggregation of the resin powder is suppressed and at a time required for suppressing the aggregation of the resin powder.
- this resin powder when used for powder bed fusion bonding, it is possible to suppress the agglomeration of the resin powder when the resin powder is carried into the thin layer forming container by the carrying member to form the thin layer, , A thin layer with a more uniform thickness is obtained. Therefore, it is possible to suppress the occurrence of heating unevenness due to the energy beam of the thin layer of the resin powder, and it is possible to improve the accuracy of the modeled object.
- (A) to (d) are photographs (No. 1) showing the appearance of the resin powder after heat treatment under various heat treatment conditions.
- (A) to (c) are photographs (No. 2) showing the appearance of the resin powder after heat treatment under various heat treatment conditions.
- (A)-(b) is a graph (the 1) which shows the measured data of the differential scanning calorific value (DSC) of polypropylene.
- (A)-(b) is a graph (the 2) which shows the measured data of the differential scanning calorific value (DSC) of polypropylene.
- (A)-(b) is a graph (the 3) which shows the measured data of the differential scanning calorific value (DSC) of polypropylene.
- (A)-(b) is a graph which shows the mode of change of the differential scanning calorimetry (DSC) curve of polypropylene with heat processing time.
- (A) is data at a heat treatment temperature of 115° C.
- (b) is data at a heat treatment temperature of 120° C.
- (A) is a top view showing the powder bed fusion bonding apparatus of FIG. 7, and (b) is a cross-sectional view taken along line II of (a).
- It is sectional drawing (the 1) which shows the powder bed fusion bonding method which concerns on embodiment.
- It is sectional drawing (the 2) which shows the powder bed fusion bonding method which concerns on embodiment.
- It is sectional drawing (the 3) which shows the powder bed fusion bonding method which concerns on embodiment.
- Polypropylene, polyethylene glycol and polyethylene oxide were used. These were mixed well and then kneaded. Then, only polyethylene glycol was dissolved in the dispersion water to obtain a suspension. Then, the fine particles were separated to obtain microspheres.
- the "average particle size” means the number average particle size, and the particle size was measured using a micrograph.
- the “circularity” is a value obtained by calculating the ratio (projected area of a particle/area of a circle having the maximum length of the particle as a diameter) for each of a plurality of particles and arithmetically averaging them.
- the circularity is obtained by measuring with an image analyzer and averaging about 100 measured particles.
- each of the seven groups was heat-treated under the conditions shown in Table 1.
- the treatment temperature is the temperature of the resin powder being heated
- the treatment time is the time when the temperature is maintained.
- FIGS. 1(a) to 1(d) and FIGS. 2(a) to 2(c) The investigation results are shown in FIGS. 1(a) to 1(d) and FIGS. 2(a) to 2(c). According to the result, in the powder materials of the first to fifth samples in Table 1 (FIGS. 1(a) to (d) and FIG. 2(a)), it can be seen that adjacent particles are bonded to each other. Absent. On the other hand, in the powder material of the sixth sample in Table 1 (FIG. 2(b)), it can be seen that the particles are adjoining each other in some places, and the powder material of the seventh sample in Table 1 is observed. In FIG. 2(c), it was found that adjacent particles were bonded to each other to form a large lump while maintaining the shape of the particles.
- DSC ⁇ Differential Scanning Calorimetry
- the vertical axis of the graph shows the calorific difference between the measurement sample and the reference substance on a relative linear scale. That is, the numbers on the vertical axis represent relative values, and the amounts of change are meaningful for each sample, but comparison of absolute values is meaningless.
- the horizontal axis shows the measured temperature (°C) on a linear scale.
- the temperatures were 95°C, 102°C, 108°C, 111°C, 116°C, and 120°C, respectively.
- no local peak appears on the higher temperature side than Ts5 to Ts6.
- ⁇ Agglutination survey> The adhesion of the microspheres was examined by rubbing the microspheres of each sample obtained above between two fingers. As a result, the microspheres subjected to the third heat treatment condition to the sixth heat treatment condition in Table 1 were less sticky than the microspheres subjected to the first heat treatment condition to the second heat treatment condition in Table 1.
- the microspheres of each of the above samples are filled in a transparent sample bottle so as to fill 1/4 thereof, and the sample bottle is erected horizontally from a vertical state to collapse the microspheres (flow method).
- the resin powders of the third to sixth samples were more likely to collapse than the resin powders of the first to second samples and had good fluidity.
- agglomeration of microspheres is suppressed by heat treatment at 105° C. or higher and 120° C. or lower for 24 hours, so that the transporting member is moved to make the microspheres smooth and a thin layer having a uniform thickness. It means that it can be deployed.
- the transparent sample bottle was held at a temperature 20° C. lower than the softening point of the microsphere for 10 minutes, and the same test (temperature rising flow test) was performed.
- the effect of suppressing aggregation was remarkably exhibited. That is, the first and second samples showed almost no fluidity, while the third to sixth samples had almost the same fluidity as at room temperature. It was then tested with a sieve that passed through particles of 90 ⁇ m and smaller. As a result, the third to sixth samples were able to pass through the screen in about half the time as compared with the first to second samples, and no agglomerated particles remained on the screen. Next, an experiment was actually carried out to form a thin layer of powder material by means of a blade type carrying member using a powder bed fusion bonding apparatus.
- the results corresponding to the above survey were obtained. That is, in the resin powders of the third to sixth samples, aggregation was suppressed by the heat treatment, and no aggregated resin powder could be observed during the transportation of the resin powder. Therefore, the surface of the formed thin layer was flat. On the other hand, in the resin powders of the first and second samples, originally agglomerated resin powder was present. For this reason, the resin powder agglomerated during the transportation of the resin powder is carried as it is without being unraveled, and thus the surface of the formed thin layer has irregularities.
- FIGS. 6A and 6B are graphs of DSC curves.
- the vertical axis shows the difference in the amount of heat between the measurement sample and the reference substance on a linear scale.
- the horizontal axis shows the measured temperature (°C) on a linear scale.
- the DSC curves have various sizes, but there are local differences. A peak occurred. The local peak tended to decrease as the heat treatment time increased. On the other hand, at the heat treatment temperature of 115° C., a local peak did not occur only after the heat treatment time of 24 hours. Further, at the heat treatment temperatures of 120° C. and 125° C., no local peak was generated in the DSC curve at all heat treatment times.
- the heat treatment temperature at which a local peak does not appear on the higher temperature side than Tsi in the DSC curve, or even if a local peak appears a heat treatment condition of sufficiently large thermal energy (temperature condition: 105° C.) or more
- a heat treatment condition of sufficiently large thermal energy temperature condition: 105° C.
- the heat treatment is performed at a temperature below the heat treatment temperature (120° C.) at which adjacent particles do not bond to each other on a large scale even after the heat treatment, and at least for a time capable of changing the properties of the resin powder, the aggregation of the resin powder is suppressed You can Thereby, a thin layer having a uniform thickness can be formed.
- the heat treatment time may be at least the time required to suppress aggregation of the resin powder.
- the heat treatment time of the preheating is not sufficient, so that some change in the property of polypropylene cannot be caused.
- the temperature at which the resin powder does not soften after all, the aggregation temperature of the resin powder can be suppressed, and at least the aggregation of the resin powder is suppressed.
- the problem is solved by heat-treating the resin powder for the time required for the above.
- the melting point is specified by DSC measurement
- the temperature is 5 to 20° C. lower than the melting point, preferably 10 to 15° C. lower, and at least the time required to suppress the agglomeration of the powder material.
- the problem is solved by performing the heat treatment.
- the resin powder that has been heat-treated under the above-mentioned heat-treatment conditions for powder bed fusion bonding there is also the advantage that the preheating temperature range (modeling window) set below the softening point can be widened. The reason for this is that, based on the survey data, the softening point increases with the heat treatment temperature.
- thermoplastic resin which can be crystallized and which is softened by heating and can be deformed into another shape
- Preferred examples include polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyamides, especially various nylons such as nylon 6, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 46, polyesters such as polyethylene terephthalate.
- PET polytetrafluoroethylene
- EVA ethylene/vinyl acetate copolymer
- ABS acrylonitrile/butadiene/styrene copolymer
- nylon, polypropylene, polylactic acid, polyethylene (PE), polyethylene terephthalate (PET), ethylene/vinyl acetate copolymer (EVA) and polycaprolactone are preferable. Further, among these, nylon, polypropylene, polylactic acid and polycaprolactone are more preferable.
- biodegradable polylactic acid or polycaprolactone can be used.
- thermoplastic resin may be a mixture of two or more kinds of the same kind or different kinds of thermoplastic resins.
- a compatibilizer More preferably, a so-called polymer alloy in which the mixed state is controlled can be used in this embodiment. By using the polymer alloy, heat resistance, toughness and granulation property can be improved.
- polymer alloys include polyphenylene oxide (PPO)/polystyrene (PS), polybenzimidazole (PBI)/polyimide (PI), PPO/ABS, ABS/polycarbonate (PC), polybutylene terephthalate (PBT)/PC,
- PPO polyphenylene oxide
- PS polystyrene
- PBI polybenzimidazole
- PI polybenzimide
- PC ABS/polycarbonate
- PBT polybutylene terephthalate
- PET/PC PET/PC
- PBT/PET PBI/PI
- nylon/modified polyolefin PBT/modified polyolefin
- nylon/PPO ABS/nylon
- ABS/PBT nylon/PPO
- nylon/ABS nylon/PC.
- Advanced Polymer Material Series 3 "High-Performance Polymer Alloy", edited by The Society of Polymer Science, (1991, Maruzen).
- the powder bed fusion bonding method of the present embodiment uses the powder material that has been subjected to the heat treatment of the present embodiment before being used for modeling, and develops the powder material into a thin layer. It is characterized in that the layer forming step and the bonding layer forming step of irradiating the formed thin layer of the powder material with an energy beam to perform melt bonding to form a bonding layer are sequentially repeated.
- the powder bed fusion bonding apparatus used in the powder bed fusion bonding method is, as shown in FIG. 7, a laser beam emitting section 101 and a thin layer forming section for forming a thin layer of a powder material and fusion-bonding it with a laser beam for modeling.
- the first and second powder material storage containers 2a and 2b are joined to the left and right of the thin layer forming container 1, and the upper surfaces of all the containers 2a, 1 and 2a are flat. It is one. Then, the recoater 10 such as a blade or a roller can be moved on the upper surfaces of all the containers 2a, 1, 2a.
- the first to third lifts 7a, 7b and 5 also serving as the bottoms of the containers 2a, 2b and 1 are provided. Is installed.
- the first to third lifts 7a, 7b, 5 are respectively connected to support shafts 8a, 8b, 6 connected to a driving device (not shown), and can move up and down.
- the recoater 10 reciprocates between the left and right first and second powder material storage containers 2a and 2b, powder is formed every time one thin layer 9a is formed in the first and second powder material storage containers 2a and 2b.
- the supply side and storage side of material 9 are switched.
- the powder material 9 is placed on the first or second elevating table 7a or 7b and raised to supply the powder material 9.
- the second or first elevating table 7b or 7a is lowered, and the powder material 9 remaining after forming the thin layer 9a is removed into the second or first elevating table.
- the third lifting platform 5 is lowered to sequentially stack new bonding layers 9b.
- An irradiation means 101 for the energy beam 11 is arranged above the thin layer forming container 1.
- the energy beam 11 not only laser light but also energetic particle beam such as electron beam can be used.
- Examples of usable laser light include carbon dioxide gas laser, YAG laser light, excimer laser light, He-Cd laser light, and semiconductor-excited solid-state laser light. Of these, carbon dioxide laser light is preferable because it is easy to operate and easy to control.
- the thin layer forming container 1 is provided with a heater on the partition wall and the third lifting table 5, and heaters 4a, 4b and infrared rays are also provided around the thin layer forming container 1.
- the lamp is arranged.
- powder bed fusion bonding is performed as follows.
- the control unit 103 controls the movement of the recoater 10, the operations of the lifts 7a, 7b, 5 and the operation of the powder bed fusion bonding apparatus such as the irradiation of the laser beam 11.
- the inside and the periphery of the thin layer forming container 1 and the first and second powder material storage containers 2a and 2b are preheated by the heaters 4a and 4b shown in FIG. Good.
- the temperature of the thin layer 9a of the powder material is kept at a temperature lower than the softening point of the powder material and 5 to 100° C. lower than the melting point by preheating, so that the laser beam 11 Melt bonding can be easily performed.
- the temperature is preferably 5 to 50° C. lower than the melting point, and more preferably 5 to 30° C. lower than the melting point.
- the powder material 9 is carried out from the first powder material container 2a by the recoater 10 and carried to the thin layer forming container 1. Then, the recoater 10 is moved so that the powder material 9 is carried onto the third lift 5 in the thin layer forming container 1 and the surface thereof is leveled to form a thin layer 9a having a uniform thickness.
- the thin layer 9a having a uniform thickness and a low porosity can be originally formed with good reproducibility.
- the powder 9 that is hard to aggregate together the thin layer 9a having a uniform thickness and a low porosity can be formed with good reproducibility more effectively.
- the thickness of the thin layer 9a of the powder material is preferably 0.01 to 0.3 mm, and more preferably 0.01 to 0.1 mm in order to obtain a more precise shaped article.
- the thin layer 9a formed in the thin layer forming step is irradiated with the energy beam 11 based on the slice data of the object to be formed, and the powder material is formed. It is melted and bonded to form a bonding layer 9b.
- the atmosphere for irradiating the thin layer 9a of the powder material with the laser light 11 is not particularly limited, but for example, an atmosphere of an inert gas such as helium, argon or nitrogen can be used.
- the inert gas atmosphere is preferable because it is possible to prevent the powder material 9 from being oxidized or corroded. Irradiation can also be performed in the atmosphere.
- the powder bed fusion bonding apparatus is operated in accordance with FIGS. 9(b) to 10(b), and the recoater 10 is moved to the left side, The second bonding layer 9b and the like are formed.
- agglomeration is performed by performing heat treatment at a temperature 10 to 15° C. lower than the melting point and at least for a time required to suppress agglomeration of the powder material.
- the hardened powder material 9 is used.
- the powder material 9 when the powder material 9 is carried into the thin layer forming container 1 by the recoater 10 to form the thin layer 9a, it is possible to suppress the formation of the powder material 9 in a lump. Therefore, the surface of the formed thin layer 9a becomes flat, and the thin layer 9a having a uniform thickness is obtained. Therefore, it is possible to prevent heating unevenness of the thin layer 9a of the powder material due to the energy beam 11, and it is possible to improve the accuracy of the modeled object.
- the softening point rises, so that the preheating temperature range set below the softening point, that is, the so-called modeling window can be widened.
- the scope of the embodiments is not limited to the examples specifically shown in the above embodiments, and does not depart from the gist of the embodiments. Modifications of the above are included in the scope of the invention defined in the claims.
- the melting point and softening point of the resin powder are specified from the differential scanning calorimetry (DSC) curve, the melting point and softening point may be specified by other methods.
- DSC differential scanning calorimetry
- the various embodiments can effectively suppress the aggregation of the resin powder. It goes without saying that suppressing the aggregation of the resin powder is not used in the sense of eliminating the aggregation altogether.
- Heat treatment method (Appendix 2) 2. The heat treatment method for a powder material according to appendix 1, wherein the temperature is set to a temperature lower by 5 to 20° C. than the melting point of the resin powder. (Appendix 3) 3. The heat treatment method for a powder material according to appendix 2, wherein the material of the resin powder is polypropylene and the temperature is 105° C. or higher and 120° C. or lower. (Appendix 4) 3.
- the heat treatment method for a powder material according to appendix 2 wherein the temperature is set to a temperature 10 to 15° C. lower than the melting point of the resin powder.
- Appendix 5 5.
- Appendix 6 The heat treatment method for a powder material according to appendix 1, wherein the time is 24 hours. (Appendix 7)
- Appendix 8 8. The powder bed fusion bonding method according to appendix 7, wherein the temperature is set to a temperature 5 to 20° C. lower than the melting point of the resin powder.
- the carrying member is moved on the upper surface of the second container which is connected to the upper surface of the first container and is flush with the upper surface of the first container, and while carrying the resin powder into the second container, A step of leveling the surface to form a thin layer of the resin powder, Forming a solidified layer by irradiating the thin layer with laser light based on slice data.
- Appendix 14 14.
- Appendix 15 15.
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Abstract
Cette invention concerne un procédé de traitement thermique de matériau pulvérulent capable de supprimer l'agrégation mutuelle de particules de matériau pulvérulent lors du déplacement d'un élément de transport pour former une couche mince. La poudre de résine est soumise à un traitement thermique à une température à laquelle la poudre de résine ne se ramollit pas et à laquelle l'agrégation de la poudre de résine est supprimée pendant au moins la durée requise pour supprimer l'agrégation de la poudre de résine.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/JP2019/001567 WO2020148914A1 (fr) | 2019-01-19 | 2019-01-19 | Procédé de traitement thermique de matériau pulvérulent, procédé de fusion sur lit de poudre, et objets produits par ces procédés |
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| PCT/JP2019/001567 WO2020148914A1 (fr) | 2019-01-19 | 2019-01-19 | Procédé de traitement thermique de matériau pulvérulent, procédé de fusion sur lit de poudre, et objets produits par ces procédés |
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| WO2020148914A1 true WO2020148914A1 (fr) | 2020-07-23 |
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| JP2017007255A (ja) * | 2015-06-24 | 2017-01-12 | トヨタ自動車株式会社 | 積層造形装置 |
| JP2018196983A (ja) * | 2016-07-22 | 2018-12-13 | 株式会社リコー | 立体造形用樹脂粉末、立体造形物の製造装置、及び立体造形物の製造方法 |
| WO2019013069A1 (fr) * | 2017-07-10 | 2019-01-17 | コニカミノルタ株式会社 | Matériau en poudre et procédé de production d'un modèle tridimensionnel |
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