Supports for sintering additively manufactured parts
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-064/40
B29C-064/141
B29C-064/295
B29C-064/245
B29C-031/04
B22F-003/11
B33Y-010/00
B29C-064/165
B29K-025/00
B29C-070/16
B29C-064/118
B29C-064/209
B29K-079/00
출원번호
US-0892750
(2018-02-09)
등록번호
US-10040242
(2018-08-07)
발명자
/ 주소
Mark, Gregory Thomas
출원인 / 주소
MARKFORGED, INC.
대리인 / 주소
Lando & Anastasi, LLP
인용정보
피인용 횟수 :
0인용 특허 :
67
초록▼
A method comprising depositing, in layers, a shrinking platform formed from a composite including metal particles embedded in a first matrix, depositing shrinking supports of the composite upon the shrinking platform, forming a separation clearance dividing at least one shrinking support into fragme
A method comprising depositing, in layers, a shrinking platform formed from a composite including metal particles embedded in a first matrix, depositing shrinking supports of the composite upon the shrinking platform, forming a separation clearance dividing at least one shrinking support into fragments, depositing, from the composite, a part upon the shrinking platform and shrinking supports, depositing a separation material intervening between the part and the shrinking supports, the separation material including a ceramic powder and a second matrix, and forming, from the shrinking platform, shrinking supports, separation material, and part, a portable platform assembly in a green state, wherein the shrinking support is configured to prevent the portable platform assembly from distorting from gravitational force during sintering of the metal particles of the assembly in a brown state, and wherein the ceramic powder of the separation material is configured to separate the shrinking support from the part following sintering.
대표청구항▼
1. A method of reducing distortion in an additively manufactured part, comprising: depositing, in successive layers, a shrinking platform formed from a composite, the composite including metal particles embedded in a first matrix;depositing shrinking supports of the composite upon the shrinking plat
1. A method of reducing distortion in an additively manufactured part, comprising: depositing, in successive layers, a shrinking platform formed from a composite, the composite including metal particles embedded in a first matrix;depositing shrinking supports of the composite upon the shrinking platform;forming, in at least one shrinking support, a separation clearance dividing the at least one shrinking support into fragments;depositing, from the composite, a part upon the shrinking platform and shrinking supports;depositing a separation material intervening between the part and the shrinking supports, the separation material including a ceramic powder and a second matrix; andforming, from the shrinking platform, shrinking supports, separation material, and part, a portable platform assembly in a green state, wherein the shrinking support is configured to prevent the portable platform assembly from distorting from gravitational force during sintering of the metal particles of the portable platform assembly in a brown state, and wherein the ceramic powder of the separation material is configured to separate the shrinking support from the part following sintering. 2. The method according to claim 1, wherein the shrinking platform interconnects the shrinking supports with one another, and wherein the method further comprises: maintaining, with the first matrix and second matrix, a shape of the portable platform assembly during deposition;debinding the first matrix in the portable platform assembly from the green state to the brown state, in a first common chamber;transporting the portable platform assembly in the brown state to a second common chamber for sintering;sintering the portable platform assembly in the brown state to shrink at a rate uniform throughout as neighboring metal particles throughout the shape-retaining brown part assembly undergo atomic diffusion, and during sintering in the second common chamber, decomposing the second matrix to leave the ceramic powder loose via the heat of the sintering;maintaining, with the first matrix, a shape of the portable platform assembly during at least part of the sintering; andmaintaining, with the ceramic powder, the shrinking supports separate from the part. 3. The method according to claim 1, wherein the separation clearance is formed as a vertical clearance separating neighboring shrinking supports and extending for substantially a height of the neighboring shrinking supports, and wherein the method further comprises: separating the neighboring shrinking supports from one another along the vertical clearance. 4. The method according to claim 1, wherein the first matrix and the second matrix are at least partially debindable by a common debinder. 5. The method according to claim 1, wherein forming the separation clearance comprises forming the fragments as blocks separable from one another along the separation clearance contiguous within a plane intersecting the shrinking supports. 6. The method according to claim 1, wherein depositing shrinking supports comprises forming a lateral support shell of the composite as the shrinking supports to follow a lateral contour of the part. 7. The method according to claim 6, further comprising: connecting the lateral support shell to the lateral contour of the part by forming separable attachment protrusions of the composite between the lateral support shell and the part. 8. The method according to claim 6, further comprising: dividing the lateral support shell into shell fragments;debinding the first matrix sufficient to form a portable assembly in the brown state including the shrinking platform, shrinking supports, lateral support shell, and part;separating the lateral support shell into the shell fragments; andseparating the shell fragments from the part. 9. The method according to claim 1, further comprising: depositing the separation material to intervene at a non-horizontal surface of the part opposing a surface of the shrinking supports, the non-horizontal surface of the part including at least one of a vertical surface, a curved surface, and a surface angled with respect to horizontal. 10. The method according to claim 1, further comprising: providing a sliding powder layer below the shrinking platform, of equal or larger surface area than a bottom of the shrinking platform, the sliding powder layer configured to reduce lateral resistance between the shrinking platform and an underlying surface during sintering. 11. A method of reducing distortion in an additively manufactured part, comprising: depositing, in successive layers, a shrinking platform formed from a composite, the composite including metal particles, a first binder component, and a second binder component;depositing, from the composite, a part supported by the shrinking platform, the shrinking platform forming a foundation that holds the part and is configured, during shrinking of the composite, to prevent movement of the shrinking platform versus the part;depositing a first shrinking support of the composite upon a first portion of the part and supporting a second portion of the part;depositing a separation material intervening between the part and the first shrinking support, the separation material including a ceramic powder and a third binder component, wherein the third binder component is responsive to a same debinder as the first binder component;forming, in the first shrinking support, a separation clearance dividing the first shrinking support into fragments separable along the separation clearance; andforming the shrinking platform, first shrinking support, separation material, and part as a portable platform assembly in a green state, wherein the first binder component and third binder component are configured to maintain a shape of the portable platform assembly during depositing of the portable platform assembly, wherein the first shrinking support is configured to prevent the portable platform assembly from distorting from gravitational force during sintering of the metal particles of the portable platform assembly in a brown state, and wherein the separation material is configured to separate the first shrinking support from the part during sintering and powderize to permit the first shrinking support to be removed from the part after sintering. 12. The method according to claim 11, further comprising: depositing second shrinking supports of the composite upon the shrinking platform, wherein the shrinking platform interconnects the shrinking supports with one another; anddepositing the separation material intervening between the part and the second shrinking supports, wherein the second shrinking supports are included in the portable platform assembly in the green state, and the ceramic powder of the separation material is configured to separate the second shrinking support from the part following sintering. 13. The method according to claim 11, further comprising: depositing the separation material intervening directly between the part and the shrinking platform, wherein the ceramic powder of the separation material is configured to separate the part from the shrinking platform following sintering. 14. The method according to claim 11, further comprising: maintaining, with the first binder component and second binder component, a shape of the portable platform assembly during deposition;debinding the first binder component in the platform assembly from a green state to a brown state, in a first common chamber;transporting the portable platform assembly in the brown state to a second common chamber;sintering, in the second common chamber, the portable platform assembly in the brown state to shrink at a rate uniform throughout as neighboring metal particles throughout the shape-retaining brown part assembly undergo atomic diffusion and the second binder decomposes in the heat of sintering; anddecomposing the third binder component to leave the ceramic powder loose in the second common chamber. 15. The method according to claim 11, wherein the separation clearance is formed as a vertical clearance extending for substantially a height of the first shrinking support, and wherein the method further comprises separating the fragments from one another along the vertical clearances. 16. The method according to claim 11, wherein forming the separation clearance comprises forming the fragments as blocks separable from one another along a separation clearance contiguous within a plane intersecting the first shrinking support. 17. The method according to claim 11, wherein depositing the first shrinking support comprises forming a lateral support shell of the same composite as the first shrinking support to follow a lateral contour of the part. 18. The method according to claim 17, further comprising: dividing the lateral support shell into shell fragments; andseparating the shell fragments from the part. 19. The method according to claim 11, wherein depositing the separation material comprises depositing the separation material to intervene at a non-horizontal surface of the part opposing a surface of the first shrinking support, the non-horizontal surface of the part including at least one of a vertical surface, a curved surface, and a surface angled with respect to horizontal. 20. The method according to claim 11, further comprising: providing a sliding powder layer below the shrinking platform, of equal or larger surface area than a bottom of the shrinking platform, the sliding powder layer configured to reduce lateral resistance between the shrinking platform and an underlying surface during sintering. 21. A method of reducing distortion in an additively manufactured part, comprising: feeding a composite including metal particles, a first binder and a second binder;feeding a separation material including ceramic powder and a third binder;depositing a portable platform assembly formed from the composite in a green state, the portable platform assembly including a shrinking platform, first shrinking supports, second shrinking supports, separation material and a part, the shrinking platform interconnecting the first shrinking supports with one another, the part deposited upon the first shrinking supports, the second shrinking supports supporting an upper portion of the part upon a lower portion of the part, and the separation material separating the part from the first shrinking supports and the second shrinking supports;maintaining a shape of the portable platform assembly during deposition with the first binder, second binder, and third binder;forming a separation clearance during deposition dividing at least one of the second shrinking supports into fragments;debinding the first binder to debind the platform assembly from a green state to a brown state; andsintering the platform assembly in the brown state to shrink at a rate uniform throughout the portable platform assembly as interconnected by the shrinking platform, and to decompose the second binder and the third binder, wherein the relative shape of the platform assembly is maintained versus gravitational force by the first shrinking supports and the second shrinking supports, and wherein the third binder is decomposed during sintering to powderize the separation material leaving a loose ceramic powder separating the part from the first shrinking supports and the second shrinking supports. 22. The method according to claim 21, further comprising: depositing the separation material in the portable platform assembly intervening directly between the part and the shrinking platform, wherein the loose ceramic powder separates the part from the shrinking platform following sintering. 23. The method according to claim 21, wherein forming the separation clearance comprises forming the separation clearance as a vertical clearance extending for substantially a height of the at least one second shrinking support, and wherein the method further comprises separating the fragments from one another along the vertical clearances. 24. The method according to claim 21, wherein forming the separation clearance comprises forming the fragments as blocks separable from one another along the separation clearance contiguous within a plane intersecting the first shrinking support. 25. The method according to claim 21, further comprising: forming a lateral support shell of the same composite as the first shrinking support to follow a lateral contour of the part. 26. The method according to claim 25, further comprising: dividing the lateral support shell into shell fragments; andseparating the shell fragments from the part. 27. The method according to claim 21, further comprising: depositing the separation material to intervene at a non-horizontal surface of the part opposing a surface of the first shrinking support, the non-horizontal surface of the part including at least one of a vertical surface, a curved surface, and a surface angled with respect to horizontal. 28. The method according to claim 21, further comprising: providing a sliding powder layer below the shrinking platform, of equal or larger surface area than a bottom of the shrinking platform, that reduces lateral resistance between the shrinking platform and an underlying surface during sintering. 29. The method according to claim 28, wherein the underlying surface comprises a portable build plate, and wherein the method further comprises: forming the shrinking platform above the portable build plate;forming the sliding powder layer below the shrinking platform and above the portable build plate with the release material; andkeeping the portable platform assembly together with the portable build plate as a unit during deposition, debinding, and sintering. 30. The method according to claim 21, wherein the metal particles in the composite are distributed in at least two sizes.
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