System, apparatus, and methods for managing sintering supports

Patent metadata

Field	Value
Publication number	US-11701710-B2
Application number	US-202117145695-A
Country	US
Kind code	B2
Filing date	Jan 11, 2021
Priority date	Jan 10, 2020
Publication date	Jul 18, 2023
Grant date	Jul 18, 2023

Abstract

Systems, apparatus and methods of additively manufacturing objects are disclosed. Specifically, provided herein are methods of heating objects having a particle-based support at least partially surrounding the object during portions of stages of the heating. Additionally, systems, apparatus, and methods for removing the particle-based support during heating, such that the object can continue heating to form a final part. Systems, apparatus, and methods for distributing the particle-based support to shore the objects through heating are disclosed. Systems, apparatus, and methods for removing the particle-based support are also disclosed herein.

First claim

What is claimed is:

1. A method of additively manufacturing a three-dimensional object, comprising steps of:
providing a part comprising a model material and one or more binder components within a volume of a heating apparatus;
adding a particle-based support to the volume such that the part is at least partially surrounded, the particle-based support comprising a pliable particle based support;
heating the part to a first temperature to form a pre-sintered object that possesses at least sufficient strength to retain its printed shape without the particle-based support; and
removing the particle-based support from about the pre-sintered object.

2. The method of claim 1 , further comprising heating the pre-sintered object to a second temperature such that a densified three-dimensional object is formed.

3. The method of claim 1 , wherein heating to the first temperature includes forming necks to connect neighboring particle surfaces of the model material.

4. The method of claim 3 , further comprising fluidizing the particle-based support around the part such that the particle-based support provides a buoyant force to the part.

5. The method of claim 4 , wherein fluidizing the particle-based support occurs following the onset of the necks connecting neighboring particle surfaces of the model material.

6. The method of claim 1 , wherein the model material comprises sinterable particles.

7. The method of claim 6 , wherein the first temperature is an initial sintering temperature of the model material.

8. The method of claim 1 , wherein the model material is characterized by a melting temperature that is lower than a melting temperature of the particle-based support.

9. The method of claim 1 , wherein adding the particle-based support includes depositing the particle-based support in the volume such that the particle-based support at least partially surrounds the part to fill gaps, overhangs, cantilevered portions, and/or unsupported ranges or spans of the part.

10. The method of claim 9 , further comprising supporting, with the particle based support, the cantilevered portions, gaps, overhangs, and/or unsupported ranges or spans of the part against deformation.

11. The method of claim 10 , wherein supporting the cantilevered portions, gaps, overhangs, and/or unsupported ranges or spans of the part against deformation includes supporting against sagging, slumping with gravity under a weight of the part, or combinations thereof.

12. The method of claim 9 , wherein the depositing comprises at least one of pouring, spreading, or rolling.

13. The method of claim 12 , wherein the depositing further comprises vibrating or shaking the volume.

14. The method of claim 9 , wherein depositing the particle-based support permits the particle-based support to occupy a volume between a surface of a build chamber and an opposing unsupported surface of the part or occupy a volume between a supported surface of model material and an opposing unsupported surface of model material.

15. The method of claim 9 , wherein heating to the first temperature results in the crumbling of the particle-based support between the pre-sintered object's cantilevered portions, gaps, overhangs, and/or unsupported ranges or spans when pressure is applied by the pre-sintered object at about the first temperature.

16. The method of claim 1 , wherein the model material comprises metal particles.

17. The method of claim 1 , wherein the one or more binder components comprises a polymer-based binder.

18. The method of claim 1 , wherein the particle-based support is a ceramic.

19. The method of claim 1 , further comprising applying a flow of gas to the particle-based support at a flow rate lower than a force needed to fluidize the particle-based support.

20. The method of claim 19 , wherein the flow of gas is applied to the particle-based support during heating to the first temperature.

21. The method of claim 1 , wherein removing the particle-based support comprises vacuuming the particle-based support out of the volume.

22. The method of claim 1 , wherein removing the particle-based support further comprises vibrating the particle-based support from about the pre-sintered object.

23. The method of claim 1 , wherein removing the particle-based support further comprises propelling the particle-based support from about the pre-sintered object.

24. The method of claim 23 , wherein propelling the particle-based support comprises applying a compressed gas to the particle-based support.

25. The method of claim 1 , further comprising receiving, with holes and/or ports positioned in a base of the volume, used particle-based support.

26. The method of claim 25 , further comprising collecting, using a secondary chamber, receptacle, repository, or cistern positioned beneath or adjacent to the volume and in communication with the holes and/or ports positioned in the base of the volume, used particle-based support.

27. The method of claim 1 , wherein the heating to the first temperature includes softening the pliable particle-based support such that it compresses between the cantilevered portions, gaps, overhangs, and/or unsupported ranges or spans of the pre-sintered object when pressure is applied by the pre-sintered object at about the first temperature.

28. A method of additively manufacturing a three-dimensional object, comprising steps of:
providing a part comprising a model material and one or more binder components within a volume of a heating apparatus;
adding a particle-based support to the volume such that the part is at least partially surrounded;
heating the part to a first temperature to form a pre-sintered object that possesses at least sufficient strength to retain its printed shape without the particle-based support, where heating to the first temperature results in the evaporation of the particle-based support; and
removing the particle-based support from about the pre-sintered object.

29. A method of additively manufacturing a three-dimensional object, comprising steps of:
providing a part comprising a model material and one or more binder components within a volume of a heating apparatus;
adding a particle-based support to the volume such that the part is at least partially surrounded;
heating the part to a first temperature to form a pre-sintered object that possesses at least sufficient strength to retain its printed shape without the particle-based support, where heating to the first temperature results in the sublimation of the particle-based support; and
removing the particle-based support from about the pre-sintered object.

30. A method of additively manufacturing a three-dimensional object, comprising steps of:
providing a part comprising a model material and one or more binder components within a volume of a heating apparatus;
adding a particle-based release material to the volume such that the part is at least partially surrounded;
heating the part to a first temperature to form a pre-sintered object that possesses at least sufficient strength to retain its printed shape without the particle-based release material, the particle-based release material powderizing when heated to the first temperature to reduce stress in the pre-sintered object during sintering; and
removing the particle-based release material from about the pre-sintered object.

Assignees

• Markforged Inc

Inventors

• Mark Gregory Thomas
• Hoffman Christopher
• Gallup Benjamin Hodsdon
• Seleznev Maxim
• Chao Michelle Ling

Classifications

• B22F10/14 Primary

  by jetting of binder onto a bed of metal powder · CPC title

• B22F10/43

  characterised by material · CPC title

• B22F10/64

  by thermal means (control of energy beam parameters for post heating B22F10/364) · CPC title

• B22F10/66

  by mechanical means · CPC title

• B22F10/68

  Cleaning or washing · CPC title