	US 11,969,938 B2
	Three-dimensional printed composites using engineered powders
Robert Swartz, Highland Park, IL (US); Eugene Gore, Des Plaines, IL (US); Buckley Crist, Wilmette, IL (US); Michael Vasquez, Chicago, IL (US); and John Bayldon, Evanston, IL (US)
Assigned to Impossible Objects, Inc., Northbrook, IL (US)
Filed by Impossible Objects, Inc., Northbrook, IL (US)
Filed on Jan. 28, 2020, as Appl. No. 16/775,267.
Claims priority of provisional application 62/797,898, filed on Jan. 28, 2019.
Prior Publication US 2020/0406538 A1, Dec. 31, 2020
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 64/147 (2017.01); B29C 64/153 (2017.01); B29C 64/165 (2017.01); B29C 64/245 (2017.01); B29C 64/295 (2017.01); B29K 23/00 (2006.01); B29K 25/00 (2006.01); B29K 33/00 (2006.01); B29K 71/00 (2006.01); B29K 79/00 (2006.01); B29K 81/00 (2006.01); B29K 101/10 (2006.01); B29K 105/00 (2006.01); B29K 707/04 (2006.01); B32B 5/02 (2006.01); B32B 5/26 (2006.01); B33Y 10/00 (2015.01); B33Y 70/00 (2020.01); B33Y 70/10 (2020.01); B33Y 80/00 (2015.01)

CPC B29C 64/147 (2017.08) [B29C 64/153 (2017.08); B29C 64/165 (2017.08); B29C 64/245 (2017.08); B29C 64/295 (2017.08); B32B 5/022 (2013.01); B32B 5/024 (2013.01); B32B 5/26 (2013.01); B33Y 10/00 (2014.12); B33Y 70/10 (2020.01); B33Y 80/00 (2014.12); B29K 2023/06 (2013.01); B29K 2023/12 (2013.01); B29K 2025/06 (2013.01); B29K 2033/12 (2013.01); B29K 2071/00 (2013.01); B29K 2079/085 (2013.01); B29K 2081/04 (2013.01); B29K 2101/10 (2013.01); B29K 2105/0097 (2013.01); B29K 2707/04 (2013.01); B29K 2713/00 (2013.01); B29K 2995/0094 (2013.01); B32B 2260/023 (2013.01); B32B 2260/046 (2013.01); B32B 2264/10 (2013.01); B33Y 70/00 (2014.12)]

16 Claims

1. A three-dimensional article of manufacture comprising a plurality of substrate layers that are infiltrated or coated by, and bound together by, a hardened material formed by heating at least one engineered powder, such that the hardened material has a material composition that is different from the material composition of any of the plurality of substrate layers, wherein the engineered powder comprises plurality of toner powder particles comprised of at least one thermoplastic or thermosettable polymer produced by at least one process permitting sufficient control of the shape, size, and composition of each powder particle to produce a powder having particles of predesigned, relatively uniform shape, size, and composition, the process further not requiring mechanical abrasion, the process further comprising chemical reaction, wherein all of the plurality of substrate layers have a substantially identical material composition and each substrate layer is a sheet that has a material composition comprising fibers held together by binder.