Powder and Method for the Preparation of Three-Dimensional Objects

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This patent describes a novel powder and its preparation method for use in creating three-dimensional (3D) objects, particularly through additive manufacturing techniques like selective laser sintering. The core invention revolves around 'supraparticles,' which are agglomerates of much smaller thermoplastic polymer nanoparticles (and optionally other organic/inorganic nanoparticles), engineered to have excellent flowability and packing properties. The powder production uses a bottom-up approach involving dispersion and spray drying, allowing precise control of particle size, composition, and morphology. These features enable more reliable, customizable, and higher-performance 3D printing with a wider range of materials, including biodegradable options.

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• Additive manufacturing (3D printing) for producing plastic parts, prototypes, and end-use components with improved mechanical and dimensional accuracy.
• Fabrication of biodegradable 3D printed items, supporting medical, environmental, or packaging applications.
• Production of composite materials with precisely distributed nanoscale additives for improved material properties (e.g., strength, conductivity, color, or antimicrobial effects).
• Manufacturing of components that require tailored mechanical, thermal, or surface properties via control over powder morphology and composition.
• Creation of customized powders for use in selective laser sintering (SLS) or other powder bed fusion techniques in automotive, aerospace, consumer goods, and biomedical fields.

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• Significantly improved powder flowability and higher packing density, leading to better accuracy and mechanical properties in 3D printed objects.
• Broader choice of usable polymer materials for additive manufacturing, including biodegradable polymers, beyond standard polyamides.
• Ability to customize the composition and morphology of the powder at the nanoscale, enabling tailored performance and multifunctional parts (e.g., with specific color, filler, or active compound distribution).
• Production method does not substantially alter the polymer's inherent properties (unlike traditional grinding), helping preserve the desired thermal and mechanical characteristics.
• Enables precise mixing and distribution of different materials within each supraparticle, leading to more homogeneous parts and reduced anisotropy compared to conventional blended powders.

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Patent Abstract

The present invention is relates to a powder for the preparation of three-dimensional objects comprising or consisting of supraparticles comprising at least a first population of first primary particles, wherein the first primary particles are thermoplastic polymeric particles, wherein the first primary particles have a volume-averaged median particle diameter (x50,3) of from 10 to 2000 nm; wherein the primary particles are agglomerated and/or partially sintered together to form the supraparticles, and/or wherein the supraparticles have a volume-averaged median particle diameter (x50,3) of from 2.5 to 100 µm. The invention also relates to a method for preparing a powder for the preparation of three-dimensional objects, a powder for the preparation of three-dimensional objects obtainable by the method for preparing a powder for the preparation of three-dimensional objects, the use of a powder for the production of a three-dimensional object, a three-dimensional object made of the powder for additive manufacturing, and a method for producing a three-dimensional object.