Dtm Corporation

General Electric Company

Kevin P McAlea

Paul F Forderhase

Angelo J Magistro

Elmer D Dickens, Jr

Glenn A Taylor

Biing Lin Lee

Hendra Ng

Thomas L Evans

Eric J Pearce

Todd D Cook

Richard B Booth

Robert S Gilmore

Andrew Jay Salem

Frederic W Kunig

Udaykumar Lakshminarayan

Barbara J McKinley

Dean S Matsumoto

Mark E Ganninger

A laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 .mu.m, provided further that the number average ratio of particles smaller than 53 .mu.m is greater than 80%, the remaining larger particles being in the size range from 53 .mu.m to 180 .mu.m. A powder with slow recrystallization rates, as evidenced by non-overlapping or slightly overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10.degree. C. to 20.degree. C. per minute, will also result in sintered parts that are near-fully dense, with minimal dimensional distortion.

Sinterable semi-crystalline powder and near-fully dense article formed

A powder for use in selective laser sintering, from which prototype articles and masters for molds may be formed, is disclosed. The powder is formed by spray drying a polymer emulsion to yield a distribution of particles of substantially spherical shape. The powder is then air classified to remove excessively small particles from the distribution; the powder may also be screened to remove large particles therefrom, as well. The resulting distribution of particle sizes, by volume, preferably has a mean particle size of between about 20.mu. and about 50.mu., with preferably less than about 5% (by volume) of its particles with a size of less than about 15.mu. and less than about 2% (by volume) of its particles with a size of greater than about 75.mu.. The powder is subjected to selective laser sintering to produce an article of approximately 55% to 75% of theoretical density. The article may be used as a prototype article or part, or as a pattern or master for a mold.

Selective laser sintering of polymer powder of controlled particle size

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.

Method of forming three-dimensional articles using thermosetting

A composite powder specially adapted for use in selective laser sintering is disclosed. The composite powder includes a polymer powder dry mixed with a reinforcement powder, where the polymer powder has a melting temperature substantially lower than that of the reinforcement powder. In the case where nearfully dense parts are to be formed, the first constituent powder is preferably a semi-crystalline powder, for example nylon 11, of a composition suitable for forming near-fully dense parts when used unblended in selective laser sintering; if porous parts are desired, the polymer powder is an amorphous powder, such as polycarbonate, polystyrene, acrylates, and styrene/acrylate copolymers. The reinforcement powder is preferably microspheres of glass, preferably coated to enhance wetting and adhesion with the polymer powder when selective laser sintering is performed. Besides improving the stiffness and heat resistance of the part produced, the composite powder widens the process window over that provided by unblended powder, provides improved dimensional accuracy in the part produced, and facilitates roughbreakout and smooth finishing of the part produced.

Selective laser sintering with composite plastic material

A laser-sinterable powder product has been prepared having unique properties which allow the powder to be sintered in a selective laser sintering machine to form a sintered part which is near-fully dense. For most purposes, the sintered part is indistinguishable from another part having the same dimensions made by isotropically molding the powder. In addition to being freely flowable at a temperature near its softening temperature, a useful powder is disclosed that has a two-tier distribution in which substantially no primary particles have an average diameter greater than 180 .mu.m, provided further that the number average ratio of particles smaller than 53 .mu.m is greater than 80%, the remaining larger particles being in the size range from 53 .mu.m to 180 .mu.m. A powder with slow recrystallization rates, as evidenced by non-overlapping endothermic and exothermic peaks in their differential scanning calorimetry characteristics for scan rates of on the order of 10.degree. C. to 20.degree. C. per minute, will also result in sintered parts that are near-fully dense, with minimal dimensional distortion.

An ultrasonic measurement device and a method for a non-destructive evaluation of polymer composites having discontinuous fibers distributed therein. The device has one or a plurality of substantially matched pairs of transducers disposed on wedge shaped focuser and a relay, the focuser and relay each have their impedances substantially matched to that of the polymer composite being analyzed. The device is placed on a surface of the composite with the apexes of the focuser and relay in close contact with the surface. A velocity of a substantially longitudinal ultrasonic wave generated by the first transducer and received by the second transducer after its passage through the composite is determined at several angles of orientations about a center point, and the measured velocities of the ultrasonic wave are processed through a computer having software to determine the physical attributes of the composite, such as weight percentage of fibers present in the composite, Young's modulus, shear modulus and Poisson's ratio of the composite.

Ultrasonic device and method for non-destructive evaluation of polymer

The crystallinity of polyesters prepared from macrocyclic poly(1,4-butylene terephthalate) oligomers is reduced and cracking of molded parts suppressed by the incorporation therein of at least one other linear or macrocyclic poly(alkylene dicarboxylate) oligomer, such as poly(ethylene terephthalate) or poly(1,4-butylene isophthalate). It is preferably employed in macrocyclic form. The resulting compositions can be combined with inert fillers and polymerized.

Macrocyclic polyester compositions convertible to linear polyesters of

Thermoplastic polyester composites are prepared from compositions comprising a filler, at least one macrocyclic poly(alkylene dicarboxylate) oligomer and a polymerization catalyst therefor. The use of polyester oligomer mixtures is preferred, and they may be present in liquid or solid form. The polyester composites prepared therefrom are characterized by excellent properties including solvent resistance.

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Austin, TX, United States of America

Kevin P McAlea