Managing powder mobility in binder jetting for additive manufacturing

Patent metadata

Field	Value
Publication number	US-11858210-B2
Application number	US-202217956207-A
Country	US
Kind code	B2
Filing date	Sep 29, 2022
Priority date	Jan 9, 2018
Publication date	Jan 2, 2024
Grant date	Jan 2, 2024

Abstract

Devices, systems, and methods are directed to the use of vapor phase change in binder jetting processes for forming three-dimensional objects. In general, a vapor of a first fluid may be directed to a layer of a powder spread across a build volume. The vapor may condense to reduce mobility of the particles of the powder of the layer. For example, the condensing vapor may reduce the likelihood of particle ejection from the layer and, thus, may reduce the likelihood of clogging or otherwise degrading a printhead used to jet a second fluid (e.g., a binder) to the layer. Further, or instead, the condensing vapor may increase the density of the powder in the layer which, when repeated over a plurality of layers forming a three-dimensional object, may reduce the likelihood of slumping of the part during sintering.

First claim

The invention claimed is:

1. A method of forming an object using binder jet additive manufacturing, the method comprising:
forming a layer of powder within a build chamber;
generating a first fluid in a vapor phase within the build chamber;
adjusting or maintaining an environment within the build chamber to affect a condensation of the first fluid from the vapor phase to a liquid phase;
condensing the first fluid from the vapor phase to the liquid phase on at least a portion of the layer of powder; and
traversing a print head relative to the layer of powder and depositing a predetermined pattern of a binder in the layer of powder.

2. The method of claim 1 , wherein adjusting or maintaining the environment within the build chamber includes controlling a temperature of at least a portion of the layer of powder to below a dew point of the first fluid in the vapor phase.

Assignees

• Desktop Metal Inc

Inventors

• Sachs Emanuel Michael
• Hudelson George
• Hoisington Paul A
• Renner Christopher Benjamin
• Vaillancourt Keith Roy
• Moynihan Edward Russell

Classifications

• B29C64/165 Primary

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B22F1/148

  Agglomerating · CPC title

• B22F10/00

  Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) · CPC title

• B22F10/14

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

• B22F10/32

  of the atmosphere, e.g. composition or pressure in a building chamber · CPC title