Apparatus, system and method of imparting specified characteristics to additively manufactured foam

Abstract

The disclosed exemplary apparatuses, systems and methods provide a three-dimensional foam molding, produced via a layer-by-layer additive manufacturing process in which regions of respective layers of pulverant are selectively melted via introduction of electromagnetic energy. These apparatuses, systems and methods may include layers of the pulverant comprising at least thermoplastic polyurethane polymer (TPU) coated upon a base particle, wherein the TPU is coated via one of spray drying and a fluidized vessel.

1 . A product comprising:
 a plurality of successive powder layers configured for a layer-by-layer additive manufacturing at least partially of foam, powder of the successive powder layers comprising:
 a compound particle including:
 a base particle; and 
 a polymer coating on the base particle configured to form a foam particle by sacrificing the base particle upon receipt of electromagnetic energy targeted to the polymer coating, the electromagnetic energy additionally fusing a plurality of the foam particles into the foam. 
 
   
     
     
         2 . The product of  claim 1 , wherein the base particle is a gas to provide voids within the plurality of layers. 
     
     
         3 . The product of  claim 1 , wherein the base particle is a solid. 
     
     
         4 . The product of  claim 1 , wherein the powder layers comprise additives. 
     
     
         5 . The product of  claim 4 , wherein the additives comprise at least one of glass beads, glass fibers, carbon fibers, carbon black, metal oxides, copper metals, flame retardants, antioxidants, pigments, and flow aids. 
     
     
         6 . The product of  claim 1 , wherein the polymer is thermoplastic polyurethane polymer (TPU). 
     
     
         7 . A product comprising:
 a plurality of successive powder layers configured for a layer-by-layer additive manufacturing at least partially of foam, ones of the powders of the successive powder layers comprising:
 a compound particle including:
 a base particle; and 
 a polymer coating on the base particle configured to form a foam particle by sacrificing the base particle upon receipt of electromagnetic energy targeted to the polymer coating, the electromagnetic energy additionally sintering a plurality of the foam particles into the foam. 
 
   
     
     
         8 . The product of  claim 1 , wherein the base particle is a gas to provide voids within the plurality of layers. 
     
     
         9 . The product of  claim 1 , wherein the base particle is a solid. 
     
     
         10 . The product of  claim 9 , wherein the base particle is one of a glass bead and a hollowed polymer. 
     
     
         11 . The product of  claim 7 , wherein the powder layers comprise additives. 
     
     
         12 . The product of  claim 11 , wherein the additives comprise at least one of glass beads, glass fibers, carbon fibers, carbon black, metal oxides, copper metals, flame retardants, antioxidants, pigments, and flow aids. 
     
     
         13 . The product of  claim 1 , wherein the polymer is thermoplastic polyurethane polymer (TPU). 
     
     
         14 - 20 . (canceled) 
     
     
         21 . A method comprising the steps of:
 placing base particles into a vessel, wherein the base particles are fluidized using a gas with a controlled flow;   placing a polymer into a solution, wherein the solvent of the solution serves as a medium to coat the base particle, wherein the polymer is soluble in the solvent of the solution; and   spraying the solution into the vessel to coat the base particles.   
     
     
         22 . The method of  claim 21 , wherein the solvent of the solution is non-participatory. 
     
     
         23 . The method of  claim 21 , wherein the solvent of the solution is participatory. 
     
     
         24 . The method of  claim 23 , wherein the participatory solution is at least one of an acid, a base, or a nucleophile. 
     
     
         25 . The method of  claim 21 , wherein the solution comprises an organic solution. 
     
     
         26 . The method of  claim 25 , wherein the organic solution comprises at least one of water, THF, MEK, and cyclohexanone. 
     
     
         27 . The method of  claim 21 , wherein the polymer is thermoplastic polyurethane polymer (TPU).