3d printers and feedstocks for 3d printers

Abstract

This disclosure relates in general to three dimensional (“3D”) printers having a configuration that prepares a three-dimensional object by using a feedstock comprising a metal or a polymer compound and a carbon coating formed on a surface of the compound. This disclosure also relates to such feedstocks and their preparation methods. This disclosure further relates to 3D composite objects prepared by using such printers and feedstocks. This disclosure also relates to carbon containing photocurable formulations and methods for their preparation. This disclosure further relates to electrically conducting 3D polymer composites prepared by using such carbon containing photocurable formulations.

1 . A three dimensional (“3D”) printer having a configuration that: dispenses a feedstock; deposits a layer of the feedstock on a surface; delivers an electromagnetic radiation to selected areas of the feedstock layer; and prepares a three-dimensional composite object; wherein the feedstock comprises a metal compound and a coating formed on a surface of the metal compound; wherein the coating has a thickness; wherein the coating absorbs the delivered electromagnetic radiation at a selected area of the feedstock layer, converts the absorbed electromagnetic radiation to heat, and transfers the heat to the metal compound thereby heating the selected area of the feedstock layer, and causing the feedstock to bond to each other and the surface on which it is deposited, and thereby forming a bonded feedstock layer. 
     
     
         2 . The 3D printer of  claim 1 , further having a configuration that deposits a layer of the feedstock on a surface of the bonded feedstock layer formed before; and forms another bonded feedstock layer according to  claim 1 . 
     
     
         3 . The 3D printer of  claim 1 , wherein the coating comprises a carbon. 
     
     
         4 . The 3D printer of  claim 1 , wherein the coating comprises a nanocarbon, a pyrolytic carbon, a graphite, an activated carbon, an amorphous carbon, a carbon fiber, or a combination thereof. 
     
     
         5 . The 3D printer of  claim 1 , wherein the coating comprises a nanocarbon. 
     
     
         6 . The 3D printer of  claim 1 , wherein the coating comprises a non-agglomerated nanocarbon. 
     
     
         7 . The 3D printer of  claim 1 , wherein the coating comprises a nanocarbon; and wherein the nanocarbon comprises a carbon nanotube, a graphene, a fullerene, or a combination thereof. 
     
     
         8 . The 3D printer of  claim 1 , wherein the coating comprises a carbon nanotube; and wherein the carbon nanotube comprises a single-wall carbon nanotube, a double-wall carbon nanotube, a multi-wall carbon nanotube, or a combination thereof. 
     
     
         9 . The 3D printer of  claim 1 , wherein the coating comprises a nanocarbon; and wherein the nanocarbon comprises a graphene, wherein the graphene comprises a single layer graphene, a double layer graphene, a multilayer graphene, a graphene strip, or a combination thereof. 
     
     
         10 . The 3D printer of  claim 1 , wherein the coating comprises a fullerene, and wherein the fullerene comprises a C 60 , a C 70 , a C 76 , a C 78 , a C 84 , or a combination thereof. 
     
     
         11 . The 3D printer of  claim 1 , wherein the metal compound comprises titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, ruthenium, rhodium, palladium, aluminum, indium, gallium, tin, silver, gold, platinum, lead, bismuth, steel, bronze, brass, or a combination thereof. 
     
     
         12 . The 3D printer of  claim 1 , wherein the metal compound comprises a metal particle, a metal wire, a metal tube, a metal sheet, or a combination thereof. 
     
     
         13 . The 3D printer of  claim 1 , wherein absorbance of the coating is higher than absorbance of the metal compound. 
     
     
         14 . The 3D printer of  claim 1 , wherein absorbance of the coating is at least 50 percent higher than the absorbance of the metal compound. 
     
     
         15 . The 3D printer of  claim 1 , wherein absorbance of the coating is at least 100 percent higher than the absorbance of the metal compound. 
     
     
         16 . The 3D printer of  claim 1 , wherein absorbance of the coating is at least 500 percent higher than the absorbance of the metal compound. 
     
     
         17 . The 3D printer of  claim 1 , wherein absorbance of the coating is at least 800 percent higher than the absorbance of the metal compound. 
     
     
         18 . The 3D printer of  claim 1 , wherein heating rate of the feedstock comprising the metal compound and the coating is higher than that of a feedstock comprising the metal compound with no coating. 
     
     
         19 . The 3D printer of  claim 1 , wherein heating rate of the feedstock comprising the metal compound and the coating is at least 50 percent higher than that of a feedstock comprising the metal compound with no coating. 
     
     
         20 . The 3D printer of  claim 1 , wherein heating rate of the feedstock comprising the metal compound and the coating is at least 100 percent higher than that of a feedstock comprising the metal compound with no coating. 
     
     
         21 . The 3D printer of  claim 1 , wherein heating rate of the feedstock comprising the metal compound and the coating is at least 500 percent higher than that of a feedstock comprising the metal compound with no coating. 
     
     
         22 . The 3D printer of  claim 1 , wherein heating rate of the feedstock comprising the metal compound and the coating is 800 percent higher than that of a feedstock comprising the metal compound with no coating. 
     
     
         23 . The 3D printer of  claim 1 , wherein the coating is sufficiently thick to substantially absorb electromagnetic radiation, but not too thick to cause defects in the composite object and thereby negatively impact properties of the composite object. 
     
     
         24 . The 3D printer of  claim 1 , wherein the coating thickness is in the range of 10 nanometers to 100 micrometers. 
     
     
         25 . The 3D printer of  claim 1 , wherein the coating thickness is in the range of 100 nanometers to 10 micrometers. 
     
     
         26 . The 3D printer of  claim 1 , wherein the coating thickness is in the range of 1 micrometer to 5 micrometers. 
     
     
         27 . The 3D printer of  claim 1 , wherein the 3D printer emits the electromagnetic radiation with power less than or equivalent to 5,000 watts. 
     
     
         28 . The 3D printer of  claim 1 , wherein the 3D printer emits the electromagnetic radiation with power less than or equivalent to 1,000 watts. 
     
     
         29 . The 3D printer of  claim 1 , wherein the 3D printer emits the electromagnetic radiation with power less than or equivalent to 500 watts. 
     
     
         30 . The 3D printer of  claim 1 , wherein the 3D printer emits the electromagnetic radiation with power less than or equivalent to 100 watts. 
     
     
         31 . A three dimensional (“3D”) printer having a configuration that: dispenses a feedstock; deposits a layer of the feedstock on a surface; delivers an electromagnetic radiation to selected areas of the feedstock layer; and prepares a three-dimensional composite object; wherein the feedstock comprises a metal compound and a coating formed on the metal compound, said coating comprising nanocarbons including nanotubes, wherein said coating is substantially free of any dispersion solvent, and wherein the coating has a thickness in the range of 10 nanometers to 100 micrometers. 
     
     
         32 . The three dimensional (“3D”) printer of  claim 31 , wherein the carbon nanotube comprises a single-walled carbon nanotube, a multi-wall carbon nanotube, or a combination thereof. 
     
     
         33 . The three dimensional (“3D”) printer of  claim 31  wherein the G/D ratio of the nanocarbons in the coating is approximately the same or higher than the G/D ratio of said nanocarbons in their initial state. 
     
     
         34 . A method of preparing a three-dimensional composite object using a three dimensional (“3D”) printer, comprising, dispensing a feedstock comprised of a metal compound and a coating thereon; depositing a layer of feedstock on a surface; delivering electromagnetic radiation to selected areas of the feedstock layer such that the feedstock and the material of the surface on which it is deposited bond together; wherein the feedstock is prepared by dispersing nanocarbons including carbon nanotubes in a solvent to form a slurry without any surfactants, dispersing agents or functional groups; applying the slurry to one or more surfaces of a metal compound; allowing the slurry to dry and form a coating on the one or more surfaces of the metal compound; and, wherein the amount of the slurry applied to the metal compound is sufficient to result in a dried coating having a thickness in the range of 10 nanometers to 100 micrometers. 
     
     
         35 . A method of preparing a three-dimensional composite object using a three dimensional (“3D”) printer of  claim 33  wherein the G/D ratio of the nanocarbons in the coating is approximately equal to or higher than the G/D ratio of the nanocarbons prior to dispersion into the slurry. 
     
     
         36 . A method of preparing a three-dimensional composite object using a three dimensional (“3D”) printer of  claim 33  wherein the feedstock metal compound comprises titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, ruthenium, rhodium, palladium, aluminum, indium, gallium, tin, silver, gold, platinum, lead, bismuth, steel, bronze, brass, or a combination thereof.