Thermoplastic Binder System and Method for 3D Manufacturing of Ceramic Components, Metallic Components or Components Based on Metal-Ceramic Composite Materials or Material Composites

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a new filament composition and manufacturing method for thermoplastic 3D printing of ceramic, metallic, or metal-ceramic composite parts. The filament uses a specific binder system containing polyethylene, stearic acid, lignin sulfonate, and cellulose, combined with various powders, to enable layer-by-layer additive manufacturing of advanced materials. The process allows for the production of complex and stable components that require later debinding and sintering to achieve their final properties.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacture of custom ceramic components for electronics, automotive, or aerospace industries using 3D printing.
• Production of metal parts or metal-ceramic composite parts with complex geometries for machinery or tooling.
• Rapid prototyping of advanced materials for research and development.
• Fabrication of medical implants or devices made from ceramics or metal-ceramic materials with precise and customizable shapes.
• Production of functional components with tailored material combinations (e.g., combining strength and heat resistance) using additive manufacturing.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables 3D printing of ceramics, metals, and metal-ceramic composites with conventional FFF/FDM printers.
• Provides a binder system with improved structural stability and flexibility, facilitating better handling and printing performance.
• Allows processing at relatively low debinding temperatures (below 500°C), reducing energy costs and risks.
• Reduces unwanted reactions (e.g., carbide formation) during sintering due to optimized powder and binder composition.
• Facilitates production of parts with high density and quality after sintering, supporting demanding industrial requirements.
• Adaptable to a broad range of powder particle sizes and material compositions, increasing versatility.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a filament for the thermoplastic 3D printing of ceramics or metals or metalloceramic composite materials or material composites via a layer-by-layer construction from a binder system, containing polyethylene, stearic acid, lignin sulfonate and cellulose, and ceramic, metallic and/or metalloceramic powders, wherein the binder system contains 5 to 25 wt.% of polyethylene, 0.5 to 4 wt.% of stearic acid, 0.1 to 1.5 wt.% of lignin sulfonate and 1 to 6 wt.% of cellulose, based on the mass of the filament.