Three-dimensional printed composites using substrates with sodium silicate binder

Abstract

A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material. Each substrate layer is a sheet-like structure that comprises fibers held together by a sodium silicate binder. The substrate layer material may be non-woven or woven. The substrate layer may be a non-woven fiber veil bound by a sodium silicate binder. The fibers may optionally include carbon fibers, ceramic fibers, polymer fibers, glass fibers, metal fibers, or a combination thereof.

What is claimed is: 
     
         1 . A three-dimensional article of manufacture comprising a plurality of woven substrate layers that are infiltrated or coated by, and bound together by, a hardened material, such that the hardened material has a material composition that is different from the material composition of any of the plurality of woven substrate layers, wherein all of the plurality of woven substrate layers have a substantially identical material composition and each woven substrate layer is a sheet-like structure that has a material composition comprising fibers held together by binder consisting only of sodium silicate. 
     
     
         2 . The article of manufacture of  claim 1 , wherein the woven substrate layer material composition includes fibers selected from the group consisting of carbon fibers, ceramic fibers, polymer fibers, glass fibers, and metal fibers. 
     
     
         3 . 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 all of the plurality of substrate layers have a substantially identical material composition and each substrate layer is a sheet-like structure that has a material composition comprising fibers held together by binder consisting only of sodium silicate. 
     
     
         4 . The article of manufacture of  claim 3 , wherein the engineered powder comprises at least one emulsion aggregation powder. 
     
     
         5 . An article of manufacture comprising a woven substrate layer that is a sheet-like structure having a material composition comprising fibers held together by binder consisting only of sodium silicate. 
     
     
         6 . The article of manufacture of  claim 5 , wherein the fibers are selected from the group consisting of carbon fibers, ceramic fibers, polymer fibers, glass fibers, and metal fibers. 
     
     
         7 . A substrate layer for an additive manufacturing process comprising one or more of carbon fiber and fiberglass, wherein the substrate layer has a substantially identical material composition throughout and is sheet-like, further having a material composition comprising fibers held together by binder consisting only of sodium silicate.