US20220305726A1 - System and method of additively manufacturing an object - Google Patents
System and method of additively manufacturing an object Download PDFInfo
- Publication number
- US20220305726A1 US20220305726A1 US17/839,656 US202217839656A US2022305726A1 US 20220305726 A1 US20220305726 A1 US 20220305726A1 US 202217839656 A US202217839656 A US 202217839656A US 2022305726 A1 US2022305726 A1 US 2022305726A1
- Authority
- US
- United States
- Prior art keywords
- build material
- powder bed
- accordance
- bonding agent
- heat source
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 238000000034 method Methods 0.000 title description 20
- 239000000463 material Substances 0.000 claims abstract description 77
- 239000000843 powder Substances 0.000 claims abstract description 65
- 239000007767 bonding agent Substances 0.000 claims abstract description 50
- 239000000203 mixture Substances 0.000 claims abstract description 17
- 239000007787 solid Substances 0.000 claims abstract description 8
- 239000002245 particle Substances 0.000 claims description 33
- 230000008018 melting Effects 0.000 claims description 21
- 238000002844 melting Methods 0.000 claims description 21
- 238000010438 heat treatment Methods 0.000 claims description 18
- 230000003064 anti-oxidating effect Effects 0.000 claims description 6
- FBAFATDZDUQKNH-UHFFFAOYSA-M iron chloride Chemical compound [Cl-].[Fe] FBAFATDZDUQKNH-UHFFFAOYSA-M 0.000 claims description 5
- -1 titanium hydride Chemical compound 0.000 claims description 5
- 229910000048 titanium hydride Inorganic materials 0.000 claims description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 3
- 229910052796 boron Inorganic materials 0.000 claims description 3
- 238000010894 electron beam technology Methods 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 239000010703 silicon Substances 0.000 claims description 3
- 239000000654 additive Substances 0.000 description 17
- 230000000996 additive effect Effects 0.000 description 17
- 230000004913 activation Effects 0.000 description 7
- 230000006870 function Effects 0.000 description 7
- 230000001965 increasing effect Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 230000008859 change Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 230000007246 mechanism Effects 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
- 238000011960 computer-aided design Methods 0.000 description 3
- 238000000354 decomposition reaction Methods 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- GQPLMRYTRLFLPF-UHFFFAOYSA-N Nitrous Oxide Chemical compound [O-][N+]#N GQPLMRYTRLFLPF-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 239000012298 atmosphere Substances 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 210000003739 neck Anatomy 0.000 description 2
- 238000012805 post-processing Methods 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- 206010024769 Local reaction Diseases 0.000 description 1
- 239000012190 activator Substances 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000001272 nitrous oxide Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/141—Processes of additive manufacturing using only solid materials
- B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/10—Formation of a green body
- B22F10/16—Formation of a green body by embedding the binder within the powder bed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
- B22F12/40—Radiation means
- B22F12/41—Radiation means characterised by the type, e.g. laser or electron beam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/245—Platforms or substrates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/255—Enclosures for the building material, e.g. powder containers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/268—Arrangements for irradiation using laser beams; using electron beams [EB]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/264—Arrangements for irradiation
- B29C64/277—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED]
- B29C64/282—Arrangements for irradiation using multiple radiation means, e.g. micromirrors or multiple light-emitting diodes [LED] of the same type, e.g. using different energy levels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/295—Heating elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/386—Data acquisition or data processing for additive manufacturing
- B29C64/393—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
- B33Y50/02—Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the field of the disclosure relates generally to additive manufacturing and objects formed therefrom and, more specifically, to additively manufacturing an object from a mixture of a build material and a thermally activated bonding agent.
- Additive manufacturing is a technology that enables “3D-printing” of objects from various materials, such as metallic powder.
- additive manufacturing processes such as direct metal laser melting (DMLM)
- DMLM direct metal laser melting
- an object is built layer-by-layer by leveling a powder bed and selectively melting predetermined portions of the powder bed using a high-powered laser. After each layer is fused, additional powder is leveled and the laser fuses the next layer, thereby fusing it to the prior layers to fabricate a complete object buried in the powder bed.
- DMLM may be a time-consuming process capable of producing a limited number of objects within a certain time frame.
- an object is built layer-by-layer by leveling a powder bed and selectively applying adhesive to predetermined portions of the powder bed. After each layer is adhered, additional powder is leveled and additional adhesive is applied to the powder bed to form a green compact. Upon removal of the green compact from the powder bed, multiple heating steps are then performed to remove the adhesive and to solidify the green compact.
- the green compact prior to solidification, the green compact has limited strength and durability, which exposes the green compact to the risk of damage. As such, the green compact must be handled carefully during and after removal from the powder bed, which can be a laborious and complex task.
- a system for use in additively manufacturing an object includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent.
- the system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent.
- the heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.
- a method of additively manufacturing an object includes providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state.
- the method also includes heating the compact object in an oven to sinter the build material and form a densified object.
- an object additively manufactured by a process including the following steps.
- the steps include providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state.
- the steps also include heating the compact object in an oven to sinter the build material and form a densified object.
- FIG. 1 is a block diagram of an exemplary additive manufacturing system
- FIG. 2 is a flow diagram illustrating an exemplary method of additively manufacturing an object.
- Approximating language may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value.
- range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
- Embodiments of the present disclosure relate to additively manufacturing a compact object from a mixture of a build material and a thermally activated bonding agent.
- the mixture is used to form a powder bed within a build chamber, and the bonding agent is responsive to heat to cause the build material to be pre-sintered or pre-joined to form a compact object.
- the compact object is formed by heating predetermined portions of the powder bed to a temperature that facilitates joining the particles of the build material to each other metallurgically while maintaining the build material in a solid state.
- the metallurgical bond that joins the particles of the build material to each other facilitates forming the compact object having a greater build strength and durability relative to green compacts formed by other known methods.
- a reduced amount of energy may be used to heat the powder bed to pre-sinter the build material.
- a plurality of low power laser beams may be emitted from a multiplexed array to facilitate increasing the build speed for the compact object.
- the manufacturing process described herein enables the use of vigorous depowdering techniques, and reduces the need for certain post-processing steps, as a result of the compact object's high strength and chemically inert bonding.
- compact object refers to an object made of build material powder that has been metallurgically bonded but that has not yet been fully sintered or densified.
- FIG. 1 is a block diagram of an exemplary additive manufacturing system 100 .
- additive manufacturing system 100 includes a build chamber 102 having a moveable build platform 104 .
- a compact object 106 is fabricated within build chamber 102 on top of moveable build platform 104 , as will be explained in further detail.
- Additive manufacturing system 100 also includes a heat source 108 and a controller 110 .
- a powder bed 112 is contained within build chamber 102 , and activation energy 114 generated by heat source 108 selectively heats powder bed 112 to facilitate manufacturing compact object 106 .
- Compact object 106 is then provided to a depowdering system 115 to remove powder bed material from the surfaces of compact object 106 .
- compact object 106 is then heated in an oven 116 to form a further solidified, densified, and/or sintered object 118
- Heat source 108 may include a laser emitter configured to emit a laser beam (i.e., activation energy 114 ) towards powder bed 112 , a spray device configured to apply an activator or catalyst to powder bed 112 , an electrical heater, a light source, or a source of radiation.
- the laser emitter may include a multiplexed array (e.g., a linear or area array of low power (i.e., less than 1 Watt), solid state, on chip lasers) capable of emitting a plurality of laser beams towards powder bed 112 .
- heat source 108 may include a projection raster heating device, an electron beam projector, and a spark heating device. As such, the build rate of compact object 106 may be increased.
- Additive manufacturing system 100 also includes a gas source 120 in flow communication with build chamber 102 .
- Gas source 120 facilitates forming an inert atmosphere within build chamber 102 for use during the additive manufacturing process.
- the inert atmosphere may be formed from a gas such as, but not limited to, helium, argon, hydrogen, oxygen, nitrogen, air, nitrous oxide, ammonia, carbon dioxide, and combinations thereof.
- Data file 122 may be in any form that enables additive manufacturing system 100 to function as described herein.
- data file 122 may be a computer aided design (CAD) file or scan data.
- CAD computer aided design
- scan data is converted into a different file format, such as a stereolithographic or standard triangle language (“STL”) file format.
- STL stereolithographic or standard triangle language
- the STL format file is then processed by a slicing program to produce an electronic file that converts the three-dimensional electronic representation of compact object 106 into an STL format file that includes compact object 106 represented as two-dimensional slices.
- the layer information generated from this process is transmitted to controller 110 , and controller 110 controls the operation of moveable build platform 104 and heat source 108 , for example, to facilitate manufacturing compact object 106 .
- a portion of moveable build platform 104 may be moved (i.e., lowered) within build chamber 102 . Thereafter, additional powder bed material may be deposited within build chamber 102 and then heated using activation energy 114 . Each time a subsequent layer of powder bed material is deposited within build chamber 102 , a recoater arm (not shown) may be used to smooth the layer such that the layer forms a substantially planar surface within build chamber 102 . The layer is then heated in each successive build cycle.
- Powder bed 112 is formed from any material that enables additive manufacturing system 100 to function as described herein.
- powder bed 112 is formed from a mixture including a substantially uniform distribution of a build material and a bonding agent in powder or particulate form.
- the build material forms the primary structure of compact object 106
- the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms, as will be described in more detail below.
- the mixture may include any ratio of build material to bonding agent that enables additive manufacturing system 100 to function as described herein.
- the mixture may include less than about 50 percent, less than about 40 percent, less than about 30 percent, between about 10 percent and about 50 percent, or between about 20 percent and about 40 percent of the bonding agent by volume of the mixture.
- both the build material and the bonding agent are a metallic material.
- Example build material includes, but is not limited to, a nickel-based material or a cobalt-based material.
- the melting point of the build material is equal to or greater than about 1000° C. Alternatively, the melting point of the build material may be less than 1000° C. in other embodiments.
- the bonding agent may be any material that enables additive manufacturing system 100 to function as described herein.
- the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms.
- the mechanisms include, but are not limited to, phase change, decomposition, diffusion, and reaction.
- Phase change occurs when the bonding agent has a lower melting point than the build material.
- the melting point of the bonding agent may be less than about 1000° C., or less than about 500° C. As such, the bonding agent is meltable at a lower temperature than the build material to facilitate the formation of metallurgical bonds between particles of the build material to form compact object 106 .
- build material can diffuse rapidly in molten bonding agent to facilitate creating the metallurgical bonds, and non-melting phase change enables higher diffusion and bonding. Formation of the metallurgical bonds facilitates enhancing the strength and durability of compact object 106 .
- the bonding agent has a melting point that is approximately equal to, or greater than, the melting point of the build material.
- heat source 108 and/or individual emitters included in heat source 108 , emits activation energy 114 therefrom having a maximum output that facilitates partially sintering the build material together by the bonding agent.
- the maximum output may provide an amount of activation energy 114 to powder bed 112 that is a predetermined percentage of a volumetric heating value required to melt the build material.
- the predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges.
- the maximum output may also provide activation energy 114 for heating the powder bed to a temperature that is greater than a melting point of the bonding agent, but that is also a predetermined percentage of a value of a melting point of the build material.
- the predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges.
- a plurality of laser beams may be emitted from a multiplexed array, having a power level within the noted ranges, to facilitate increasing the build speed for the compact object using a heat source that is less costly and that requires less power to operate when compared to energy sources that melt metallic build material, such as those used in direct metal laser melting devices.
- the bonding agent is a sintering aid that enables particles of the build material to be bonded to each other via one or more mechanisms, such as decomposition.
- Decomposition occurs when particles having high surface energy are created to enable rapid bonding to the build material.
- the bonding agent is formed from a compound that includes a bonding component and an antioxidation component.
- the bonding component bonds the particles of the build material together, and the antioxidation component removes surface oxides from the build material.
- the presence of oxides on the particles of the build material makes it difficult to bond the particles to each other. Removing the oxides from the particles facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other.
- compact object 106 is manufactured with an enhanced strength and durability.
- Example bonding agents include, but are not limited to, titanium hydride, iron chloride, a low melt alloy material such as standard braze powders, and combinations thereof.
- titanium hydride When heated, titanium hydride thermally decomposes into its titanium and hydrogen components.
- the titanium component facilitates providing the metallurgical bond between the particles of powder bed 112
- the hydrogen component facilitates cleaning the particles of the build material of oxides.
- iron chloride may be included in the mixture as a standalone additive, or as a coating applied to the particles of the build material.
- iron chloride thermally decomposes to its iron and chlorine components. The iron component facilitates providing the metallurgical bond between the particles of powder bed 112 .
- diffusion is initiated via the addition of boron or silicon, for example, to powder bed 112 as a melting point depressant. Additionally, reaction occurs when a thermal barrier is overcome and local reaction, or intermetallic formation, of the build particles occurs.
- the bonding agent in the mixture may have any average particle size that enables additive manufacturing system 100 to function as described herein.
- surface energy and average particle size are inversely proportional relative to each other.
- reducing the average particle size of the bonding agent facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other.
- increasing the surface energy of the particles of powder bed 112 may also facilitate the formation of metallurgical bonds therebetween.
- powder bed 112 is heated to a temperature that partially, but not fully, melts the particles of the bonding agent.
- the bonding agent has an average particle size of less than about 10 microns.
- FIG. 2 is a flow diagram illustrating an exemplary method 200 of additively manufacturing object 118 (shown in FIG. 1 ).
- Method 200 includes providing 202 a powder bed formed from a mixture of a build material and a bonding agent.
- Method 200 also includes selectively heating 204 the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object.
- the bonding agent is responsive to heat, but does not need to be melted to pre-sinter or pre-join the build material, which enables a reduced amount of energy to be used to heat the powder bed.
- the compact object is depowderized, and method 200 further includes heating 206 the compact object in an oven to melt the build material and form the object.
- An exemplary technical effect of the systems and methods described herein includes at least one of: (a) high speed manufacturing of green compacts having enhanced durability and strength; (b) eliminating the need for adhesive burnout post-processing steps; (c) high speed manufacturing of green compacts using a reduced power output; and (d) forming chemically inert and metallurgical bonds in the green compact to provide the enhanced durability and strength.
- Exemplary embodiments of systems and methods for use in additively manufacturing an object are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein.
- the methods and systems may also be used in combination with other additive manufacturing systems, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications, equipment, and systems that may benefit from the technical effects recited herein.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Optics & Photonics (AREA)
- Physics & Mathematics (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Toxicology (AREA)
- Health & Medical Sciences (AREA)
- Plasma & Fusion (AREA)
- General Health & Medical Sciences (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Powder Metallurgy (AREA)
Abstract
Description
- The field of the disclosure relates generally to additive manufacturing and objects formed therefrom and, more specifically, to additively manufacturing an object from a mixture of a build material and a thermally activated bonding agent.
- Additive manufacturing is a technology that enables “3D-printing” of objects from various materials, such as metallic powder. In some known additive manufacturing processes, such as direct metal laser melting (DMLM), an object is built layer-by-layer by leveling a powder bed and selectively melting predetermined portions of the powder bed using a high-powered laser. After each layer is fused, additional powder is leveled and the laser fuses the next layer, thereby fusing it to the prior layers to fabricate a complete object buried in the powder bed. However, DMLM may be a time-consuming process capable of producing a limited number of objects within a certain time frame. In other known additive manufacturing processes, such as binder jetting, an object is built layer-by-layer by leveling a powder bed and selectively applying adhesive to predetermined portions of the powder bed. After each layer is adhered, additional powder is leveled and additional adhesive is applied to the powder bed to form a green compact. Upon removal of the green compact from the powder bed, multiple heating steps are then performed to remove the adhesive and to solidify the green compact. However, prior to solidification, the green compact has limited strength and durability, which exposes the green compact to the risk of damage. As such, the green compact must be handled carefully during and after removal from the powder bed, which can be a laborious and complex task.
- In one aspect, a system for use in additively manufacturing an object is provided. The system includes a powder bed configured for containment within a build chamber, wherein the powder bed is formed from a mixture of a build material and a bonding agent. The system also includes a heat source configured to selectively heat the powder bed to a temperature such that the build material is at least partially sintered together by the bonding agent. The heat source also selectively heats the powder bed to the temperature that maintains the build material in a solid state.
- In another aspect, a method of additively manufacturing an object is provided. The method includes providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state. The method also includes heating the compact object in an oven to sinter the build material and form a densified object.
- In yet another aspect, an object additively manufactured by a process including the following steps is provided. The steps include providing a powder bed formed from a mixture of a build material and a bonding agent, and selectively heating the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object, wherein the temperature is selected to maintain the build material in a solid state. The steps also include heating the compact object in an oven to sinter the build material and form a densified object.
- These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
-
FIG. 1 is a block diagram of an exemplary additive manufacturing system; and -
FIG. 2 is a flow diagram illustrating an exemplary method of additively manufacturing an object. - Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
- In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
- The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
- “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
- Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
- Embodiments of the present disclosure relate to additively manufacturing a compact object from a mixture of a build material and a thermally activated bonding agent. The mixture is used to form a powder bed within a build chamber, and the bonding agent is responsive to heat to cause the build material to be pre-sintered or pre-joined to form a compact object. Thus, the compact object is formed by heating predetermined portions of the powder bed to a temperature that facilitates joining the particles of the build material to each other metallurgically while maintaining the build material in a solid state. The metallurgical bond that joins the particles of the build material to each other facilitates forming the compact object having a greater build strength and durability relative to green compacts formed by other known methods. In addition, in embodiments where the bonding agent has a lower melting point than the build material, a reduced amount of energy may be used to heat the powder bed to pre-sinter the build material. As such, a plurality of low power laser beams may be emitted from a multiplexed array to facilitate increasing the build speed for the compact object. In addition, the manufacturing process described herein enables the use of vigorous depowdering techniques, and reduces the need for certain post-processing steps, as a result of the compact object's high strength and chemically inert bonding.
- As used herein, the term “compact object” refers to an object made of build material powder that has been metallurgically bonded but that has not yet been fully sintered or densified.
-
FIG. 1 is a block diagram of an exemplaryadditive manufacturing system 100. In the exemplary embodiment,additive manufacturing system 100 includes abuild chamber 102 having amoveable build platform 104. Acompact object 106 is fabricated withinbuild chamber 102 on top ofmoveable build platform 104, as will be explained in further detail.Additive manufacturing system 100 also includes aheat source 108 and acontroller 110. Apowder bed 112 is contained withinbuild chamber 102, andactivation energy 114 generated byheat source 108 selectivelyheats powder bed 112 to facilitate manufacturingcompact object 106.Compact object 106 is then provided to adepowdering system 115 to remove powder bed material from the surfaces ofcompact object 106. In some embodiments,compact object 106 is then heated in anoven 116 to form a further solidified, densified, and/orsintered object 118 -
Heat source 108 may include a laser emitter configured to emit a laser beam (i.e., activation energy 114) towardspowder bed 112, a spray device configured to apply an activator or catalyst topowder bed 112, an electrical heater, a light source, or a source of radiation. In one embodiment, the laser emitter may include a multiplexed array (e.g., a linear or area array of low power (i.e., less than 1 Watt), solid state, on chip lasers) capable of emitting a plurality of laser beams towardspowder bed 112. Alternatively,heat source 108 may include a projection raster heating device, an electron beam projector, and a spark heating device. As such, the build rate ofcompact object 106 may be increased. -
Additive manufacturing system 100 also includes agas source 120 in flow communication withbuild chamber 102.Gas source 120 facilitates forming an inert atmosphere withinbuild chamber 102 for use during the additive manufacturing process. For example, the inert atmosphere may be formed from a gas such as, but not limited to, helium, argon, hydrogen, oxygen, nitrogen, air, nitrous oxide, ammonia, carbon dioxide, and combinations thereof. - The form and the material buildup of
compact object 106 are determined as a function of design data embodied in adata file 122.Data file 122 may be in any form that enablesadditive manufacturing system 100 to function as described herein. For example,data file 122 may be a computer aided design (CAD) file or scan data. In some embodiments, the CAD file or scan data is converted into a different file format, such as a stereolithographic or standard triangle language (“STL”) file format. The STL format file is then processed by a slicing program to produce an electronic file that converts the three-dimensional electronic representation ofcompact object 106 into an STL format file that includescompact object 106 represented as two-dimensional slices. The layer information generated from this process is transmitted tocontroller 110, andcontroller 110 controls the operation ofmoveable build platform 104 andheat source 108, for example, to facilitate manufacturingcompact object 106. - For example, after a layer of
powder bed 112 has been processed as a result of being heated byactivation energy 114, at least a portion ofmoveable build platform 104 may be moved (i.e., lowered) withinbuild chamber 102. Thereafter, additional powder bed material may be deposited withinbuild chamber 102 and then heated usingactivation energy 114. Each time a subsequent layer of powder bed material is deposited withinbuild chamber 102, a recoater arm (not shown) may be used to smooth the layer such that the layer forms a substantially planar surface withinbuild chamber 102. The layer is then heated in each successive build cycle. -
Powder bed 112 is formed from any material that enablesadditive manufacturing system 100 to function as described herein. For example,powder bed 112 is formed from a mixture including a substantially uniform distribution of a build material and a bonding agent in powder or particulate form. The build material forms the primary structure ofcompact object 106, and the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms, as will be described in more detail below. Thus, the mixture may include any ratio of build material to bonding agent that enablesadditive manufacturing system 100 to function as described herein. For example, the mixture may include less than about 50 percent, less than about 40 percent, less than about 30 percent, between about 10 percent and about 50 percent, or between about 20 percent and about 40 percent of the bonding agent by volume of the mixture. - In the exemplary embodiment, both the build material and the bonding agent are a metallic material. Example build material includes, but is not limited to, a nickel-based material or a cobalt-based material. In some embodiments, the melting point of the build material is equal to or greater than about 1000° C. Alternatively, the melting point of the build material may be less than 1000° C. in other embodiments.
- The bonding agent may be any material that enables
additive manufacturing system 100 to function as described herein. For example, as described above, the bonding agent is a sintering aid that enables particles of build material to be bonded to each other via one or more mechanisms. The mechanisms include, but are not limited to, phase change, decomposition, diffusion, and reaction. Phase change occurs when the bonding agent has a lower melting point than the build material. The melting point of the bonding agent may be less than about 1000° C., or less than about 500° C. As such, the bonding agent is meltable at a lower temperature than the build material to facilitate the formation of metallurgical bonds between particles of the build material to formcompact object 106. For example, build material can diffuse rapidly in molten bonding agent to facilitate creating the metallurgical bonds, and non-melting phase change enables higher diffusion and bonding. Formation of the metallurgical bonds facilitates enhancing the strength and durability ofcompact object 106. In an alternative embodiment, the bonding agent has a melting point that is approximately equal to, or greater than, the melting point of the build material. - Accordingly, in some embodiments,
heat source 108, and/or individual emitters included inheat source 108, emitsactivation energy 114 therefrom having a maximum output that facilitates partially sintering the build material together by the bonding agent. For example, the maximum output may provide an amount ofactivation energy 114 topowder bed 112 that is a predetermined percentage of a volumetric heating value required to melt the build material. The predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges. - The maximum output may also provide
activation energy 114 for heating the powder bed to a temperature that is greater than a melting point of the bonding agent, but that is also a predetermined percentage of a value of a melting point of the build material. The predetermined percentage is less 100 percent, and may be defined within a range between about 60 percent and about 99 percent, within a range between about 70 percent and about 90 percent, defined within a range between about 70 percent and about 80 percent, or may be a percentage value within any of the aforementioned ranges. As such, in one embodiment, a plurality of laser beams may be emitted from a multiplexed array, having a power level within the noted ranges, to facilitate increasing the build speed for the compact object using a heat source that is less costly and that requires less power to operate when compared to energy sources that melt metallic build material, such as those used in direct metal laser melting devices. - As noted above, the bonding agent is a sintering aid that enables particles of the build material to be bonded to each other via one or more mechanisms, such as decomposition. Decomposition occurs when particles having high surface energy are created to enable rapid bonding to the build material. For example, in one embodiment, the bonding agent is formed from a compound that includes a bonding component and an antioxidation component. The bonding component bonds the particles of the build material together, and the antioxidation component removes surface oxides from the build material. In general, the presence of oxides on the particles of the build material makes it difficult to bond the particles to each other. Removing the oxides from the particles facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other. As such,
compact object 106 is manufactured with an enhanced strength and durability. Example bonding agents include, but are not limited to, titanium hydride, iron chloride, a low melt alloy material such as standard braze powders, and combinations thereof. - When heated, titanium hydride thermally decomposes into its titanium and hydrogen components. The titanium component facilitates providing the metallurgical bond between the particles of
powder bed 112, and the hydrogen component facilitates cleaning the particles of the build material of oxides. Alternatively, iron chloride may be included in the mixture as a standalone additive, or as a coating applied to the particles of the build material. When heated, iron chloride thermally decomposes to its iron and chlorine components. The iron component facilitates providing the metallurgical bond between the particles ofpowder bed 112. - Alternatively, diffusion is initiated via the addition of boron or silicon, for example, to
powder bed 112 as a melting point depressant. Additionally, reaction occurs when a thermal barrier is overcome and local reaction, or intermetallic formation, of the build particles occurs. - In addition, the bonding agent in the mixture may have any average particle size that enables
additive manufacturing system 100 to function as described herein. In general, surface energy and average particle size are inversely proportional relative to each other. Thus, reducing the average particle size of the bonding agent facilitates increasing the surface energy of the particles, which enhances the natural inclination of the particles to bond to each other. In addition, increasing the surface energy of the particles ofpowder bed 112 may also facilitate the formation of metallurgical bonds therebetween. For example, in one embodiment,powder bed 112 is heated to a temperature that partially, but not fully, melts the particles of the bonding agent. It is believed, without being bound by any particular theory, that partially melting the bonding agent facilitates the creation of necks or connectors that extend from the bonding particles towards adjacent build particles. Increasing the surface energy of the particles ofpowder bed 112 facilitates reducing the temperature in which the bonding agent is caused to partially melt and create the necks or connectors. As such, the average particle size of the bonding agent is selected to achieve the aforementioned objectives. Thus, in the exemplary embodiment, the bonding agent has an average particle size of less than about 10 microns. -
FIG. 2 is a flow diagram illustrating anexemplary method 200 of additively manufacturing object 118 (shown inFIG. 1 ).Method 200 includes providing 202 a powder bed formed from a mixture of a build material and a bonding agent.Method 200 also includes selectively heating 204 the powder bed to a temperature such that the build material is at least partially sintered together to form a compact object. As described above, the bonding agent is responsive to heat, but does not need to be melted to pre-sinter or pre-join the build material, which enables a reduced amount of energy to be used to heat the powder bed. The compact object is depowderized, andmethod 200 further includesheating 206 the compact object in an oven to melt the build material and form the object. - An exemplary technical effect of the systems and methods described herein includes at least one of: (a) high speed manufacturing of green compacts having enhanced durability and strength; (b) eliminating the need for adhesive burnout post-processing steps; (c) high speed manufacturing of green compacts using a reduced power output; and (d) forming chemically inert and metallurgical bonds in the green compact to provide the enhanced durability and strength.
- Exemplary embodiments of systems and methods for use in additively manufacturing an object are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods and systems may also be used in combination with other additive manufacturing systems, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications, equipment, and systems that may benefit from the technical effects recited herein.
- Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
- This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Claims (21)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17/839,656 US20220305726A1 (en) | 2019-11-01 | 2022-06-14 | System and method of additively manufacturing an object |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/671,656 US11364679B2 (en) | 2019-11-01 | 2019-11-01 | System and method of additively manufacturing an object |
US17/839,656 US20220305726A1 (en) | 2019-11-01 | 2022-06-14 | System and method of additively manufacturing an object |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/671,656 Continuation US11364679B2 (en) | 2019-11-01 | 2019-11-01 | System and method of additively manufacturing an object |
Publications (1)
Publication Number | Publication Date |
---|---|
US20220305726A1 true US20220305726A1 (en) | 2022-09-29 |
Family
ID=75688678
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/671,656 Active 2040-01-13 US11364679B2 (en) | 2019-11-01 | 2019-11-01 | System and method of additively manufacturing an object |
US17/839,656 Pending US20220305726A1 (en) | 2019-11-01 | 2022-06-14 | System and method of additively manufacturing an object |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/671,656 Active 2040-01-13 US11364679B2 (en) | 2019-11-01 | 2019-11-01 | System and method of additively manufacturing an object |
Country Status (1)
Country | Link |
---|---|
US (2) | US11364679B2 (en) |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20170297097A1 (en) * | 2016-04-14 | 2017-10-19 | Desktop Metal, Inc. | Fabricating an interface layer for removable support |
US20180370127A1 (en) * | 2015-07-13 | 2018-12-27 | Eos Gmbh Electro Optical Systems | Method and device for producing a three-dimensional object |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6401795B1 (en) | 1997-10-28 | 2002-06-11 | Sandia Corporation | Method for freeforming objects with low-binder slurry |
DE19918282C1 (en) | 1999-04-22 | 2001-01-25 | Ald Vacuum Techn Ag | Device and method for removing binding material from metal powders |
JP5428546B2 (en) | 2009-06-04 | 2014-02-26 | 三菱マテリアル株式会社 | Method for producing aluminum composite having porous aluminum sintered body |
US11623389B2 (en) | 2017-04-21 | 2023-04-11 | Desktop Metal, Inc. | Multi-directional binder jetting additive manufacturing |
US10421124B2 (en) | 2017-09-12 | 2019-09-24 | Desktop Metal, Inc. | Debinder for 3D printed objects |
WO2019221708A1 (en) * | 2018-05-15 | 2019-11-21 | Hewlett-Packard Development Company, L.P. | Three-dimensional printing |
-
2019
- 2019-11-01 US US16/671,656 patent/US11364679B2/en active Active
-
2022
- 2022-06-14 US US17/839,656 patent/US20220305726A1/en active Pending
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180370127A1 (en) * | 2015-07-13 | 2018-12-27 | Eos Gmbh Electro Optical Systems | Method and device for producing a three-dimensional object |
US20170297097A1 (en) * | 2016-04-14 | 2017-10-19 | Desktop Metal, Inc. | Fabricating an interface layer for removable support |
Also Published As
Publication number | Publication date |
---|---|
US11364679B2 (en) | 2022-06-21 |
US20210129427A1 (en) | 2021-05-06 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
Fang et al. | Study on metal deposit in the fused-coating based additive manufacturing | |
JP6717573B2 (en) | Additive manufacturing method using fiber reinforcement | |
EP3408096B1 (en) | Laser pulse shaping for additive manufacturing | |
JP6789694B2 (en) | Additional manufacturing of joint preforms | |
US20150224607A1 (en) | Superalloy solid freeform fabrication and repair with preforms of metal and flux | |
US12064813B2 (en) | Additive manufacturing method with controlled solidification and corresponding device | |
JP2017185804A (en) | Apparatus and method for selective laser sintering of object with void | |
EP3187285B1 (en) | Powder for layer-by-layer additive manufacturing, and process for producing object by layer-by-layer additive manufacturing | |
JP2011021218A (en) | Powder material for laminate molding, and powder laminate molding method | |
Paul et al. | Metal additive manufacturing using lasers | |
US10821521B2 (en) | Article surface finishing method | |
US20120219726A1 (en) | Method and device for producing a component | |
US10384285B2 (en) | Method of selective laser brazing | |
CN108290216B (en) | Powder for 3D printing and 3D printing method | |
JP3752427B2 (en) | Solid object modeling method | |
US20170216971A1 (en) | Use of variable wavelength laser energy for custom additive manufacturing | |
Medina | Development and application of a CFD model of laser metal deposition | |
EP3766604A1 (en) | Method and device for purging an additive manufacturing space | |
Su et al. | Investigation of fully dense laser sintering of tool steel powder using a pulsed Nd: YAG (neodymium-doped yttrium aluminium garnet) laser | |
US11090861B2 (en) | Systems and methods for lateral material transfer in additive manufacturing system | |
US11364679B2 (en) | System and method of additively manufacturing an object | |
EP2918359A1 (en) | Sintering particulate material | |
JP2019039067A (en) | Continuous additive manufacture of high pressure turbine | |
EP3838444A1 (en) | Method and device for removing impurities in additive manufacture using helium and hydrogen gases | |
CN110064756A (en) | A kind of method of selective laser melting (SLM) molding |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: GENERAL ELECTRIC COMPANY, NEW YORK Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:OPPENHEIMER, SCOTT MICHAEL;DIDOMIZIO, RICHARD;KARP, JASON HARRIS;SIGNING DATES FROM 20191021 TO 20191024;REEL/FRAME:060189/0855 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: ADVISORY ACTION MAILED |