Particulate compositions comprising a metal precursor for additive manufacturing and methods associated therewith

Abstract

Additive manufacturing processes, such as powder bed fusion of thermoplastic particulates, may be employed to form printed objects in a range of shapes. It is sometimes desirable to form conductive traces upon the surface of printed objects. Conductive traces and similar features may be introduced during additive manufacturing processes by incorporating a metal precursor in a thermoplastic printing composition, converting a portion of the metal precursor to discontinuous metal islands using laser irradiation, and performing electroless plating. Suitable printing compositions may comprise a plurality of thermoplastic particulates comprising a thermoplastic polymer, a metal precursor admixed with the thermoplastic polymer, and optionally a plurality of nanoparticles disposed upon an outer surface of each of the thermoplastic particulates, wherein the metal precursor is activatable to form metal islands upon exposure to laser irradiation. Melt emulsification may be used to form the thermoplastic particulates.

What is claimed is the following: 
     
         1 . A printed object comprising:
 a polymer matrix formed by particulate consolidation and comprising a thermoplastic polymer; and   a metal precursor admixed with the polymer matrix, the metal precursor being activatable to form metal islands upon exposure to laser irradiation.   
     
     
         2 . The printed object of  claim 1 , further comprising:
 a plurality of nanoparticles admixed with the polymer matrix, the plurality of nanoparticles comprising a plurality of oxide nanoparticles, carbon black, or any combination thereof.   
     
     
         3 . The printed object of  claim 2 , wherein the plurality of oxide nanoparticles comprises a plurality of silica nanoparticles. 
     
     
         4 . The printed object of  claim 1 , wherein the metal precursor is activatable by an infrared or near-infrared pulsed laser. 
     
     
         5 . The printed object of  claim 4 , wherein the metal precursor is activatable at a wavelength ranging from about 1020 nm to about 1070 nm. 
     
     
         6 . The printed object of  claim 1 , wherein the metal precursor comprises at least one material selected from the group consisting of copper oxide; a mixed oxide of copper and a metal selected from the group consisting of antimony, aluminum, cesium, cobalt, chromium, magnesium, manganese, nickel, tin, titanium, silver, iron, zinc, and zirconium; copper chromium oxide spinel; copper aluminum oxide; copper hydroxide; copper hydroxide phosphate; copper phosphate; copper sulfate; copper thiocyanate; a metal-organic complex comprising a metal selected from the group consisting of copper, silver, palladium, and any combination thereof; and any combination thereof. 
     
     
         7 . The printed object of  claim 1 , further comprising:
 an infrared radiation absorber admixed with the thermoplastic polymer;
 wherein the infrared radiation absorber comprises a non-stoichiometric metal oxide containing a metal selected from the group consisting of antimony, bismuth, boron, indium, titanium, tin, cesium, zirconium, molybdenum, vanadium, iron, and any combination thereof. 
   
     
     
         8 . The printed object of  claim 7 , wherein the infrared radiation absorber comprises about 0.01 wt. % to about 10 wt. % of the printed object with respect to the thermoplastic polymer. 
     
     
         9 . The printed object of  claim 1 , wherein the metal precursor is dispersed as metal precursor particulates in the thermoplastic polymer, the metal precursor particulates having a particle size ranging from about 10 nm to about 1000 nm. 
     
     
         10 . The printed object of  claim 1 , wherein the metal precursor comprises about 1 wt. % to about 25 wt. % of the printed object with respect to the thermoplastic polymer.