Method of forming three-dimensional articles using thermosetting

Details Method of forming three-dimensional articles using thermosetting Method of forming three-dimensional articles using thermosetting

1995-10-13

1998-05-05

Jenkins, Daniel J.

Powder metallurgy processes

Powder metallurgy processes with heating or sintering

Making porous product

419 29, 419 35, 419 38, 419 54, 419 55, B22F 102, B22F 326

Patent

active

057490414

ABSTRACT:
A method of fabricating articles, such as prototype parts and prototype tooling for injection molding, is disclosed. The method begins with the fabrication of the article in a "green" state by the selective laser sintering, or another additive thermal process, applied to a composite powder, preferably a powder of metal particles coated with a thermoplastic polymer. Both the green article and also an aqueous emulsion of a thermosetting material are then preheated to a temperature below the glass transition temperature of the thermoplastic polymer, and the green article is then infiltrated with the aqueous emulsion. The thermosetting material may be a thermosetting polymer with an appropriate cross-linking agent, or may be a cross-linking agent that will react with the thermoplastic binder polymer. After infiltration, the article is dried, and a rigid skeleton of a thermosetting material is now present within the structure of the article. Further processing may now be performed. The article may be heated beyond the decomposition temperature of the polymers so as to drive off the polymer and sinter the metal particles to one another; alternatively, a resin may be added to the article to form a metal-polymer composite article. High strength articles may thus be formed in a manner which preserves the dimensional accuracy of the article relative to its CAD representation.

REFERENCES:
patent: 4247508 (1981-01-01), Housholder
patent: 4863538 (1989-09-01), Deckard
patent: 4944817 (1990-07-01), Bourell et al.
patent: 5017753 (1991-05-01), Deckard
patent: 5076869 (1991-12-01), Bourell et al.
patent: 5156697 (1992-10-01), Bourell et al.
patent: 5284695 (1994-02-01), Barlow et al.
Hackh's Chemical Dictionary, p. 674, 1969.

Affiliated with

Also associated with

Rating

Method of forming three-dimensional articles using thermosetting does not yet have a rating. At this time, there are no reviews or comments for this patent.

If you have personal experience with Method of forming three-dimensional articles using thermosetting, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method of forming three-dimensional articles using thermosetting will most certainly appreciate the feedback.

Rate now

Comments { 0 }

Profile ID: LFUS-PAI-O-71330