Multi-part removable support structures

Patent metadata

Field	Value
Publication number	US-2017297104-A1
Application number	US-201715469444-A
Country	US
Kind code	A1
Filing date	Mar 24, 2017
Priority date	Apr 14, 2016
Publication date	Oct 19, 2017
Grant date	—

Abstract

Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering. The support structure may be a multi-part support structure to mitigate mold lock or facilitate removal from enclosed spaces.

First claim

1 . A method comprising:
fabricating, from a first material, a support structure for an object, the support structure including two or more discrete support components; forming an interface layer including a first portion of the interface layer adjacent to the support structure and a second portion of the interface layer between the two or more discrete support components; and fabricating a surface of the object from a second material, the surface of the object adjacent to the first portion of the interface layer and the second material including a powdered material for forming a final part and a binder system including one or more binders, wherein the one or more binders resist deformation of a net shape of the object during processing of the object into the final part, wherein processing of the object into the final part includes debinding the net shape to remove at least a portion of the one or more binders and sintering the net shape to join and densify the powdered material, and wherein the interface layer resists bonding of the support structure to the object during sintering.

2 . The method of claim 1 wherein forming the interface layer includes fabricating the interface layer using at least one of fused filament fabrication, binder jetting, and stereolithography.

3 . The method of claim 1 wherein forming the interface layer includes inkjetting a ceramic-loaded slurry onto the support structure.

4 . The method of claim 1 wherein forming the interface layer includes depositing a suspension onto the support structure.

5 . The method of claim 4 wherein the suspension includes a medium resistant to sintering at a sintering temperature of the powdered material.

6 . The method of claim 4 wherein the suspension includes a selective embrittlement material that selectively embrittles a bond between the support structure and the surface of the object.

7 . The method of claim 1 wherein forming the interface layer includes at least one of inkjetting, spraying, micropipetting, and painting an interface material onto the support structure as the interface layer.

8 . The method of claim 1 wherein the interface layer includes a ceramic powder.

9 . A method comprising:
receiving an article including a support structure fabricated from a first material, an object, and an interface layer, wherein the support structure includes two or more discrete support components for supporting an the object, wherein the interface layer includes a first portion of the interface layer adjacent to the support structure and a second portion of the interface layer between the two or more discrete support components, and wherein the object includes a surface fabricated from a second material including a powdered material for forming a final part and a binder system including one or more binders, wherein the one or more binders resist deformation of a net shape of the object during processing of the object into the final part, wherein processing of the object into the final part includes sintering the net shape to join and densify the powdered material, and wherein the interface layer resists bonding of the support structure to the object during sintering; and processing the article into the final part, wherein processing the article includes at least one of debinding the article and sintering the article, and wherein processing the article further includes separating the object from the support structure at the interface layer.

10 . The method of claim 9 wherein the support structure includes a print support for the object.

11 . The method of claim 9 wherein the support structure includes a debinding support for the object.

12 . The method of claim 9 wherein the support structure includes a sintering support for the object.

13 - 20 . (canceled)

Assignees

• Desktop Metal Inc

Inventors

• Gibson Michael Andrew
• Myerberg Jonah Samuel
• Fulop Ricardo
• Chin Ricardo
• Verminski Matthew David
• Fontana Richard Remo
• Schuh Christopher Allan
• Chiang Yet-Ming
• Hart Anastasios John

Classifications

• B22F10/18

  by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF] · CPC title

• B22F10/64

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

• B22F10/28

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

• B22F10/32

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

• B22F10/40

  Structures for supporting workpieces or articles during manufacture and removed afterwards · CPC title