Particulates for additive manufacturing techniques

Patent metadata

Field	Value
Publication number	US-2016184891-A1
Application number	US-201414585504-A
Country	US
Kind code	A1
Filing date	Dec 30, 2014
Priority date	Dec 30, 2014
Publication date	Jun 30, 2016
Grant date	—

Abstract

A globule for an additive manufacturing process includes a plurality of additive manufacturing stock particles respectively having a submicron size. A binder fixes the plurality of submicron size additive manufacturing stock particles to one another such that the particles form a globule having a size of less than fifty microns.

First claim

What is claimed is:

1 . A globule for an additive manufacturing process, comprising:
a plurality of additive manufacturing stock particles of submicron size; and a binder fixing the plurality additive manufacturing stock particles to one another, wherein the plurality of additive manufacturing stock particles and the binder form a globule having a size of less than 50 microns.

2 . A globule as recited in claim 1 , wherein the binder fixes the plurality of additive manufacturing stock particles to one another within an encapsulating droplet.

3 . A globule as recited in claim 1 , wherein the binder defines a plurality of capillary bonds fixing the plurality of additive manufacturing stock particles to one another.

4 . A globule as recited in claim 1 , wherein the binder defines a plurality of funicular bonds fixing the plurality of additive manufacturing stock particles to one another.

5 . A globule as recited in claim 1 , wherein the binder defines a plurality of pendular bonds fixing the plurality of additive manufacturing stock particles to one another.

6 . A globule as recited in claim 1 , wherein the binder includes material from one of the additive manufacturing stock particles diffused over a surface of another of the plurality of additive manufacturing stock particles.

7 . A globule as recited in claim 1 , wherein the additive manufacturing stock particles include at least one of a metallic material, a ceramic material, and a polymeric material.

8 . A globule as recited in claim 1 , wherein the binder material includes water.

9 . A method of making globules for an additive manufacturing process, the method comprising:
introducing a plurality of additive manufacturing stock particles of submicron size into a spray chamber; wetting surfaces of the plurality of additive manufacturing stock particles with a binder; and agglomerating the plurality of additive manufacturing stock particles into globules having sizes of less than 50 microns.

10 . A method as recited in claim 9 , further including spraying the binder into the spray chamber and intersecting a flow of additive manufacturing stock particles with a flow of binder.

11 . A method as recited in claim 9 , further including strengthening the globules by pre-sintering the globules.

12 . A method as recited in claim 11 , wherein pre-sintering the globules includes completely evaporating the binder from the globules.

13 . An additive manufacturing method, the method comprising:
depositing a plurality of globules as recited in claim 1 into a development module of a powder bed fusing system; compressing the plurality of globules within the development module; and selectively applying thermal energy to the plurality of globules using an electron beam or laser system.

14 . A method as recited in claim 13 , further including:
fusing a portion of the plurality of the globules into an integral structure; withdrawing a piston of the development module; depositing an second plurality of globules as recited in claim 1 into the development module; compressing the additional globules into the development module; selectively applying thermal energy to a portion of the second plurality of globules using the electron beam or laser system; and fusing the portion of the second plurality of globules to form a layer of the integral structure.

15 . A method as recited in claims 13 , wherein compressing the plurality of globules within the development module includes spreading and compressing the globules using a roller.

Assignees

• Delavan Inc

Inventors

• Mironets Sergey

Classifications

• B29B13/021 Primary

  Heat treatment of powders · CPC title

• B22F1/148

  Agglomerating · CPC title

• B22F12/63

  Rollers · CPC title

• B22F10/34

  of powder characteristics, e.g. density, oxidation or flowability · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title