WO2017058181A1 - Procédé de fabrication additive par rotation - Google Patents

Procédé de fabrication additive par rotation Download PDF

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Publication number
WO2017058181A1
WO2017058181A1 PCT/US2015/053065 US2015053065W WO2017058181A1 WO 2017058181 A1 WO2017058181 A1 WO 2017058181A1 US 2015053065 W US2015053065 W US 2015053065W WO 2017058181 A1 WO2017058181 A1 WO 2017058181A1
Authority
WO
WIPO (PCT)
Prior art keywords
radial
article
recited
based material
fabrication process
Prior art date
Application number
PCT/US2015/053065
Other languages
English (en)
Inventor
Sameh DARDONA
Slade R. Culp
Wayde R. Schmidt
III William Eaton HOLDEN
Original Assignee
United Technologies Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by United Technologies Corporation filed Critical United Technologies Corporation
Priority to PCT/US2015/053065 priority Critical patent/WO2017058181A1/fr
Publication of WO2017058181A1 publication Critical patent/WO2017058181A1/fr

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/12Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of wires
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00Apparatus 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
    • B22F12/90Means for process control, e.g. cameras or sensors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00Additive 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
    • B29C64/10Processes of additive manufacturing
    • B29C64/106Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE 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
    • B33Y80/00Products made by additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10Formation of a green body
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0003Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular electrical or magnetic properties, e.g. piezoelectric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

Definitions

  • additive manufacturing involves forming a desired geometry layer-by-layer under computer control. For example, a layer of powder metal alloy or other material is deposited into a bed. Selected portions of the layer are then fused, such as by laser, according to a particular cross section of the component. The process is repeated until the entire component is built, layer-by-layer, from the bottom up.
  • a printer device and printer head are used to selectively deposit an "ink" or polymer material layer-by-layer.
  • An additive fabrication process includes rotating a core member about a central axis; while the core member is rotating, selectively depositing a first material onto the core member with respect to computerized design data representing an article to form a first radial layer of the article; and while the core member with the first radial layer is rotating, selectively depositing a second material onto the first radial layer with respect to the computerized design data to form a second radial layer of the article.
  • the first material is a metal-based material and the second material is a polymer-based material.
  • the polymer- based material includes additive particles selected from the group consisting of magnetically active additive particles, thermal conductivity modifier additive particles, and combinations thereof.
  • the selective depositing of the first material includes forming a coil of metal-based material with a constant spacing between turns of the coil of metal-based material.
  • the selective depositing of the second material includes forming a coil of polymer-based material.
  • the coil of polymer-based material is substantially closed with regard to any spacing between turns of the coil of polymer-based material.
  • a further embodiment of any of the forgoing embodiments includes selectively depositing one or more additional first radial layers and additional second radial layers with respect to the computerized design data.
  • the selective depositing of the first material, the selective depositing of the second material, or a combination thereof includes leaving at least one open space in the form of a continuous, open-ended passage in the article.
  • the continuous passage extends through at least one of the first radial layers and through at least one of the second radial layers.
  • the selective depositing of the first material, the selective depositing of the second material, or a combination thereof includes leaving at least one open space in the form of a controlled- geometry void.
  • a further embodiment of any of the foregoing embodiments includes installing an electronic device in the controlled-geometry void.
  • the selective depositing of the first material, the selective depositing of the second material, or a combination thereof includes forming the one or more additional first radial layers and additional second radial layers over the electronic device.
  • the selective depositing of at least one of the first material or of the second material includes extruding.
  • An article according to an example of the present disclosure includes a first radial layer formed of a first material.
  • the first radial layer is disposed around a central axis in a first radial layer geometry that corresponds to computerized design data of the article, and a second radial layer is formed of a second material.
  • the second radial layer is disposed around the first radial layer in a second radial layer geometry that corresponds to the computerized design data of the article.
  • the first material is a metal-based material and the second material is a polymer-based material.
  • the polymer- based material includes additive particles selected from the group consisting of magnetically active additive particles, thermal conductivity modifier additive particles, and combinations thereof.
  • the first radial layer is in a form of a coil of metal-based material with a constant spacing between turns of the coil of metal-based material
  • the second radial layer is in the form of a coil of polymer-based material that is closed with regard to any spacing between turns of the coil of polymer-based material.
  • At least one of the first radial layer and the second radial layer includes a continuous, open-ended passage.
  • a further embodiment of any of the foregoing embodiments includes one or more additional first radial layers and additional second radial layers in an alternating layer arrangement, and an electronic device embedded in the alternating layer arrangement.
  • Figure 1 illustrates an example rotary additive fabrication process.
  • Figure 2 illustrates a modification of the process of Fig. 1.
  • Figure 3 illustrates another modification that utilizes a polymer-based material with additive particles.
  • Figure 4 illustrates an example article fabricated in accordance with an example process disclosed herein to have an alternating layer arrangement.
  • Figure 5 illustrates another example process and article that has a continuous, open-ended passage.
  • Figure 6 illustrates another example process and article that has a controlled-geometry void and embedded electronic device.
  • FIG. 1 schematically illustrates an example additive fabrication process 20.
  • the disclosed process 20 is a rotary technique that can be used to build an article layer-by-layer, radially inwards out, to fabricate electromagnetic devices and the like.
  • the process 20 will be described herein with regard to hardware and/or software for carrying out the process 20. It is to be understood, however, that the hardware and software could vary depending on factors such as the article being formed and the types of deposition techniques selected for use.
  • the process 20 utilizes a first feeder 22, a second feeder 24, a rotary mechanism 26, and a controller 28 that is in communication with the first feeder 22, the second feeder 24, and the rotary mechanism 26 for controlling operation thereof.
  • the controller 28 includes software, hardware (e.g., a microprocessor, display, etc.), or both to control the position and feed rates of the feeders 22/24 and the rotational speed of the rotary mechanism 26.
  • the controller 28 can thus coordinate the operations of these components to carry out the process 20 and functions described herein.
  • the rotary device 26 rotates a core member 30 about a central axis A. While the core member 30 is rotating, the first feeder 22 selectively deposits a first material 32 onto the core member 30 with respect to computerized design data that represents the article that is being formed in order to deposit or form a first radial layer 32a of the article. Again, while the core member 30 is rotating, the second feeder 24 selectively deposits a second material 34 onto the first radial layer 32a with respect to the computerized design data to form a second radial layer 34a of the article. As can be appreciated, additional radial layers 32a/34a may be deposited in an alternating arrangement to form a multilayer, functional device, such as but not limited to, an electromagnetic device.
  • the materials 32/34 may be the same in composition, but more typically would be different compositions to build layers of different functionality, such as but not limited to, insulating and conductive layers. Additionally, although the two feeders 22/24 are shown, a single feeder may alternatively be used to deposit the first material 32 and then the second material 34.
  • the computerized design data may be Computer Aided Design (CAD) data or other computerized data that represents a portion or all of the geometry of the article.
  • the controller 28 may include the computerized design data or, alternatively, may be responsive to another controller or the like that has the computerized design data.
  • the first feeder 22, the second feeder 24, or both can be selected to deposit the first material 32 and the second material 34 in a desired geometry or configuration.
  • the first feeder 22 may be a wire feeder that feeds a wire of the first material 32 onto the core member 30.
  • the second feeder 24 may be an extruder that extrudes a filament of the second material 34 onto the first radial layer 32a.
  • the first feeder 22, the second feeder 24, or both can employ other deposition techniques of the first and second materials 32/34.
  • the first and second feeders 22/24 may be configured to feed the first and second materials 32/34 as a spray, slurry, gel, paste, film, ink, or the like.
  • the first and second feeders 22/24 can feed the first and second materials 32/34 in different cross-sectional geometries and/or at different volumes.
  • additional feeders and materials can be used to deposit additional layers or types of layers.
  • the controller 28 is configured/programmed to control the rotational speed of the core member 30 via rotary mechanism 26 and the deposition location and rate of the first and second materials 32/24 via feeders 22/24. For instance, the rotation of the core member 30 and the deposition location and rate are controlled to control the surface finish of the first radial layer 32a, the second radial layer 34a, or both. For example, rotation of the core member 30 and deposition of the first and second materials 32/34 may periodically be ceased or slowed for a predetermined amount of time to facilitate controlling surface finish of one or more of the layers 32a/34a.
  • the feeders 22 and 24 can be employed simultaneously to deposit the first and second materials 32/34 simultaneously and thus form the first and second radial layers 32a/34a simultaneously (but axially offset).
  • the selective deposition of the first and second materials 32/34 may be separated in time such that the first material 32 is first deposited to partial or full completion and the second material 34 is thereafter deposited to partial or full completion.
  • the rotational direction of the core member 30 may be reversed for one of more of the layers 32a/34a to provide an opposite winding or coil direction.
  • first and second materials 32/34 are deposited such that the first and second layers 32a/34a are in contact in the illustrated example, it will be appreciated that intermediate layers or structures could be provided radially in between the layers 32a/34a such that they do not contact or are in partial contact. Furthermore, the first and second materials 32/34, and thus the first and second layers 32a/34a, could be reversed in radial order.
  • Figure 2 depicts a further example of the process 20.
  • the first material 132 is a metal -based material and the second material 134 is a polymer-based material.
  • the polymer-based material is a thermoplastic or a thermoset.
  • the metal-based material is based on Ni, Cu, Au, or Ag, and the polymer- based material is based on epoxy, acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), nylon, polycarbonate (PC), or silicone.
  • ABS acrylonitrile butadiene styrene
  • PLA polylactic acid
  • PC polycarbonate
  • silicone silicone
  • the term "-based" used with reference to one or more materials refers to the composition of the material having a predominant amount of that constituent upon which it is based.
  • a polymer-based material and a metal-based material will have predominant amounts of, respectively, polymer and metal relative to the individual amounts of any other constituents in the compositions.
  • the location and rate of the deposition of the first material 132 and the second material 134 can be precisely controlled.
  • the first material 132 is selectively deposited as a coil of the metal-based material with a constant spacing, represented at "a," between turns of the coil of the metal-based material.
  • a uniform helical coil is one example. That is, the location on the core member 30 that the first material 132 is deposited is precisely controlled to achieve a relatively constant spacing and thus high concentricity about the axis A and enhanced performance of the end-use article.
  • the second material 134 is also selectively deposited as a coil, but of the polymer-based material.
  • the polymer coil is generally closed with regard to any spacing between the turns of the coil.
  • the successive turns of the coil are in contact with each other such that the second radial layer 134a is substantially free of any voids or holes.
  • the location and rate of deposit of the second material 134 is highly accurate, and the turns of the coil can be precisely controlled to potentially reduce voids or holes in the second radial layer 134a.
  • Figure 3 illustrates a further example in which the second material 234 is a polymer-based material that includes additive particles 236 to enhance the functionality of the second radial layer 234a.
  • the additive particles 236 are selected from magnetically active additive particles, thermal conductivity-enhancing additive particles, or combinations thereof.
  • Magnetically active additive particles are magnetic materials with a high permeability used to confine and guide magnetic fields.
  • Non-limiting examples of magnetically active particles include nickel-iron-chromium alloy, iron, soft and hard ferrite, cobalt, some alloys of rare earth metals and certain ceramics.
  • Thermal conductivity modifier additive particles are particles that modify thermal conductivity of the second radial layer 234a by, for example, either increasing or decreasing thermal conductivity of the polymer of the polymer-based material (e.g., carbon nanotubes, boron nitride, graphene, aluminum oxide, silicon carbide, aluminum nitride, glasses and ceramics). That is, the thermal conductivity additive particles have either a higher or lower thermal conductivity than the polymer.
  • the difference in thermal conductivity between that of the polymer and that of the thermal conductivity additive particles is at least +/- 10%.
  • the difference in thermal conductivity between that of the polymer and that of the thermal conductivity additive particles is +/- 10-20%, is at least +/- 100%, or is at least +/- 200% (two orders of magnitude).
  • Figure 4 illustrates a cross-section through an example end-use article 100.
  • the article 100 includes an inner or innermost first radial layer 32a and an outer or intermediate second radial layer 34a.
  • the article 100 may only have two such layers 32a/34a, as mentioned above, additional layers 32a/34a may be used.
  • the article 100 is shown with two layers 32a and two layers 34a configured in an alternating layer arrangement. Additional layers 32a/34a may also be used.
  • FIG. 5 schematically illustrates another example article 200 and modification of the process 20.
  • an open space is left in order to form a continuous, open-ended passage 40.
  • the passage 40 has a first open end 40a and a second open end 40b.
  • the first open end 40a may be in a radially inner or innermost one of the layers and the second open end 40b may be in a radially outer or outermost one of the layers.
  • the passage 40 may extend through at least one first radial layer 32a and through at least one second radial layer 34a.
  • the passage 40 may extend through only one first radial layer 32a or only one second radial layer 34a.
  • the passage 40 may serve for cooling the article 200 by natural or active convective cooling, for example.
  • a coolant can be used, the coolant selected from air, liquid or a solid-containing liquid fluid.
  • FIG. 6 illustrates another example article 300 and modification of the process 20.
  • first and second radial layers 32a/34a are selectively deposited as described.
  • at least one open space is left to form of a controlled-geometry void 302.
  • An electronic device 304 is then installed in the controlled-geometry void 302.
  • the controlled-geometry void 302 has a shape that corresponds to the shape of the electronic device 304.
  • One or more subsequent layers 32a/34a are then deposited over and/or around the electronic device 304 such that the electronic device 304 becomes embedded in the alternating layer arrangement. Multiple electronic devices 304 can be incorporated into the article 300 using this technique.
  • the electronic device 304 can be, but is not limited to, a switch or a sensor for integrating additional functionality into the article 300.
  • the sensor or sensors can include Hall sensors, temperature sensors, motion detectors, accelerometers, chemical sensors and the like.
  • the electronic device 304 is a pre-existing device that is installed into the controlled-geometry void 302.
  • the electronic device 304 can be built or deposited in-situ in the controlled-geometry void 302 by way of electronics direct write or the like.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Analytical Chemistry (AREA)
  • Automation & Control Theory (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)

Abstract

Un procédé de fabrication additive consiste à faire tourner un élément d'âme autour d'un axe central. Lorsque l'élément d'âme tourne, un premier matériau est déposé sélectivement sur l'élément d'âme en fonction de données de conception informatisée représentant un article de façon à former une première couche radiale de l'article. Lorsque l'élément d'âme pourvu de la première couche radiale tourne, un second matériau se dépose sélectivement sur la première couche radiale en fonction des données de conception informatisée de façon à former une seconde couche radiale de l'article.
PCT/US2015/053065 2015-09-30 2015-09-30 Procédé de fabrication additive par rotation WO2017058181A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2015/053065 WO2017058181A1 (fr) 2015-09-30 2015-09-30 Procédé de fabrication additive par rotation

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2015/053065 WO2017058181A1 (fr) 2015-09-30 2015-09-30 Procédé de fabrication additive par rotation

Publications (1)

Publication Number Publication Date
WO2017058181A1 true WO2017058181A1 (fr) 2017-04-06

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4323756A (en) * 1979-10-29 1982-04-06 United Technologies Corporation Method for fabricating articles by sequential layer deposition
US5545367A (en) * 1992-04-15 1996-08-13 Soane Technologies, Inc. Rapid prototype three dimensional stereolithography
US5594652A (en) * 1991-01-31 1997-01-14 Texas Instruments Incorporated Method and apparatus for the computer-controlled manufacture of three-dimensional objects from computer data
US6270849B1 (en) * 1999-08-09 2001-08-07 Ford Global Technologies, Inc. Method of manufacturing a metal and polymeric composite article
US20090206974A1 (en) * 2008-02-18 2009-08-20 Rainer Meinke Helical Coil Design and Process For Direct Fabrication From A Conductive Layer
US20150017272A1 (en) * 2013-07-15 2015-01-15 Xerox Corporation Digital Manufacturing System For Printing Three-Dimensional Objects On A Rotating Core

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4323756A (en) * 1979-10-29 1982-04-06 United Technologies Corporation Method for fabricating articles by sequential layer deposition
US5594652A (en) * 1991-01-31 1997-01-14 Texas Instruments Incorporated Method and apparatus for the computer-controlled manufacture of three-dimensional objects from computer data
US5545367A (en) * 1992-04-15 1996-08-13 Soane Technologies, Inc. Rapid prototype three dimensional stereolithography
US6270849B1 (en) * 1999-08-09 2001-08-07 Ford Global Technologies, Inc. Method of manufacturing a metal and polymeric composite article
US20090206974A1 (en) * 2008-02-18 2009-08-20 Rainer Meinke Helical Coil Design and Process For Direct Fabrication From A Conductive Layer
US20150017272A1 (en) * 2013-07-15 2015-01-15 Xerox Corporation Digital Manufacturing System For Printing Three-Dimensional Objects On A Rotating Core

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
"Lathe-Type 3D Printer", 4 June 2013 (2013-06-04), Retrieved from the Internet <URL:www.scr!bd.com/doc/147351838/Lathe-Type-3D-Printer> [retrieved on 20151130] *

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