Making Strong Ceramic-Metal Parts with Special 3D Printing Powder

Fujimi Inc.'s patent describes a special 3D printing powder made of ceramic and metal particles combined into granulated units, designed to efficiently produce high-density, strong parts.

What it covers

This patent describes an additive manufacturing material, essentially a specialized powder, for creating high-density objects through 3D printing. It combines a first powder, which is mainly ceramic, with a second powder, which is mainly a specific metal or metal alloy (Claim 9). These two powders are not just mixed; they form 'granulated particles' where the tiny 'primary particles' of ceramic and metal are bound together, leaving small spaces or 'voids' (Claim 9). The ceramic particles are also required to be smaller than the metal particles, specifically their average diameter (D1) must be half or less than half of the metal particles' average diameter (D2) (Claim 9). The metal content in these granulated particles must be between 15% and less than 90% by mass (Claim 9). For example, this material could be used to 3D print a durable, heat-resistant component for an engine or a wear-resistant tool.

What it doesn't cover

• —Does not cover additive manufacturing materials where the ceramic powder's average particle diameter is more than half the metal powder's average particle diameter (D1 > 0.5 * D2).
• —Does not cover materials where the ceramic and metal powders are simply mixed, rather than forming 'granulated particles' where primary particles are three-dimensionally bound through voids.
• —Does not cover materials where the metal component is less than 15% or 90% or more by mass of the total ceramic and metal powder content.
• —Does not cover materials using metal elements or alloys not explicitly listed in claim 9 or claim 10, such as certain rare earth metals or specific custom alloys.
• —Does not cover materials where either the first powder is not mainly ceramic or the second powder is not mainly metal.

The clever bit

The clever bit is how the ceramic and metal powders are structured: they form 'granulated particles' where tiny primary particles are bound together with specific size ratios (ceramic particles being half or less the size of metal particles) and precise metal content. This unique structure allows for efficient molding and results in high-density final products.

Why it matters

High-density parts made from ceramic and metal composites offer superior strength, heat resistance, and wear resistance, making them valuable in demanding applications. This patent aims to make it easier and more efficient to produce such complex parts using additive manufacturing. By carefully controlling the material's composition and structure, it allows for the creation of components that might be difficult or impossible to make with traditional methods.

Real-world examples

• 1.Aerospace engine components
• 2.Medical implants requiring high strength and biocompatibility
• 3.Wear-resistant industrial tooling and cutting inserts
• 4.Automotive parts for high-performance vehicles
• 5.Components for nuclear reactors or other high-temperature environments