Managing powder mobility in binder jetting for additive manufacturing

Patent metadata

Field	Value
Publication number	US-2020009788-A1
Application number	US-201916576465-A
Country	US
Kind code	A1
Filing date	Sep 19, 2019
Priority date	Jan 9, 2018
Publication date	Jan 9, 2020
Grant date	—

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

1 - 28 . (canceled)

29 . A method of forming an object using binder jet additive manufacturing, the method comprising:
forming a layer of powder on a build volume; directing a first fluid in a vapor phase toward the layer of powder; and delivering a second fluid to the layer of powder in a two-dimensional pattern, wherein the second fluid is configured to bind at least some of the powder.

30 . The method of claim 29 , further comprising condensing the first fluid from the vapor phase to a liquid phase.

31 . The method of claim 30 , wherein condensing the first fluid from the vapor phase to the liquid phase precedes delivering the second fluid to the layer of powder.

32 . The method of claim 30 , wherein the layer of powder includes a void space between particles of powder, and wherein the first fluid in the liquid phase fills anywhere from 0.1 percent of the void space to 10 percent of the void space.

33 . The method of claim 29 , wherein at least a portion of the layer of powder is maintained at a temperature less than a dew point of the first fluid.

34 . The method of claim 29 , wherein the first fluid includes one or more of water, acetone, toluene, methyl ethyl ketone, ethanol, isopropyl alcohol, or n-butyl acetate.

35 . The method of claim 29 , wherein the layer of powder is a layer of metal powder.

36 . The method of claim 29 , wherein the first fluid in the vapor phase is at a temperature less than a boiling point of the first fluid.

37 . The method of claim 29 , wherein the first fluid in the vapor phase is at a temperature greater than or equal to a boiling point of the first fluid.

38 . The method of claim 29 , wherein directing the first fluid in the vapor phase toward the layer of powder further includes directing a carrier gas toward the layer of powder.

39 . The method of claim 38 , wherein the carrier gas includes one or more of nitrogen, argon, or air.

40 . The method of claim 38 , wherein the carrier gas is passed through a sparger to mix the carrier gas with the first fluid in the vapor phase.

41 . A method of forming an object using binder jet additive manufacturing, the method comprising:
forming a layer of powder on a build volume; directing a first fluid in a vapor phase toward the layer of powder; and condensing the first fluid from the vapor phase to a liquid phase.

42 . The method of claim 41 , further comprising delivering a second fluid to the layer of powder in a two-dimensional pattern, wherein the second fluid is configured to bind at least some of the powder.

43 . The method of claim 41 , wherein the layer of powder includes a void space between particles of powder, and wherein the first fluid in the liquid phase fills anywhere from 0.1 percent of the void space to 10 percent of the void space.

44 . The method of claim 41 , wherein at least a portion of the layer of powder is maintained at a temperature less than a dew point of the first fluid.

45 . The method of claim 41 , wherein the first fluid includes one or more of water, acetone, toluene, methyl ethyl ketone, ethanol, isopropyl alcohol, or n-butyl acetate.

46 . The method of claim 41 , wherein the first fluid in the vapor phase is at a temperature less than a boiling point of the first fluid.

47 . The method of claim 41 , wherein the first fluid in the vapor phase is at a temperature greater than or equal to a boiling point of the first fluid.

48 . A method of forming an object using binder jet additive manufacturing, the method comprising:
forming a first layer of powder on a build volume; directing a first fluid in a vapor phase toward the first layer of powder; condensing the first fluid from the vapor phase to a liquid phase; delivering a second fluid to the first layer of powder in a first two-dimensional pattern, wherein the second fluid is configured to bind at least some of the powder; forming a second layer of powder on a build volume; directing the first fluid in the vapor phase toward the second layer of powder; condensing the first fluid from the vapor phase to the liquid phase; and delivering the second fluid to the second layer of powder in a second two-dimensional pattern.

Assignees

• Desktop Metal Inc

Inventors

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

Classifications

• B33Y10/00

  Processes of additive manufacturing · CPC title

• 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

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title