	US 12,233,605 B2
	Apparatus, system and method of using sacrificial microspheres to form additively manufactured foam
Nicholas Dippel, St. Petersburg, FL (US); and Luke Rodgers, St. Petersburg, FL (US)
Assigned to JABIL INC.
Appl. No. 17/311,655
Filed by JABIL INC., St. Petersburg, FL (US)
PCT Filed Dec. 6, 2019, PCT No. PCT/US2019/065051 § 371(c)(1), (2) Date Jun. 7, 2021, PCT Pub. No. WO2020/118242, PCT Pub. Date Jun. 11, 2020.
Claims priority of provisional application 62/776,341, filed on Dec. 6, 2018.
Prior Publication US 2022/0105688 A1, Apr. 7, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 64/40 (2017.01); B22F 10/28 (2021.01); B33Y 70/00 (2020.01); B33Y 70/10 (2020.01); B33Y 80/00 (2015.01); B29C 64/153 (2017.01); B29C 64/165 (2017.01); B29K 75/00 (2006.01); B29K 105/04 (2006.01); B33Y 10/00 (2015.01)

CPC B29C 64/40 (2017.08) [B22F 10/28 (2021.01); B33Y 70/00 (2014.12); B33Y 70/10 (2020.01); B33Y 80/00 (2014.12); B29C 64/153 (2017.08); B29C 64/165 (2017.08); B29K 2075/00 (2013.01); B29K 2105/04 (2013.01); B33Y 10/00 (2014.12)]

19 Claims

1. A three-dimensional porous 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, comprising:

the layers of the pulverant comprising:

at least thermoplastic polyurethane polymer (TPU) coated upon a sacrificial hollow base particle comprising a plastic microsphere comprising an acrylic copolymer, wherein a sacrifice of the sacrificial hollow base particle follows the introduction of the electromagnetic energy, to thereby create the pores of the three-dimensional porous foam molding; and

a light weight filler, wherein the TPU is coated via one of spray drying and a fluidized vessel.