Supports for sintering additively manufactured parts

Patent metadata

Field	Value
Publication number	US-2020079027-A1
Application number	US-201916550979-A
Country	US
Kind code	A1
Filing date	Aug 26, 2019
Priority date	Dec 2, 2016
Publication date	Mar 12, 2020
Grant date	—

Abstract

According to one aspect, embodiments herein provide a method of reducing distortion in an additively manufactured part comprising forming a shrinking platform from a composite including metal particles embedded in a first matrix, forming shrinking supports from the composite, forming a part from the composite upon the shrinking platform and shrinking supports, forming an interior structure in at least one of the shrinking platform, the shrinking supports, and the part having a plurality of chambers with interconnections therebetween, forming from the shrinking platform, the sintering supports, and the part a portable assembly, and debinding the first matrix in the portable assembly to form a portable assembly in a brown state, wherein debinding the first matrix includes penetrating a fluid debinder into the interior structure of the at least one of the shrinking platform, the shrinking supports, and the part to debind the first matrix from within the interior structure.

First claim

What is claimed is:

1 .- 20 . (canceled)

21 . A method of additively manufacturing a three-dimensional structure, comprising steps of:
forming a part and a shrinking platform, each of the part and the shrinking platform comprising metal particles and one or more binder components; and forming a release layer between the part and the shrinking platform, the release layer comprising a material that powderizes when the part and the shrinking platform are sintered; wherein, during sintering, the part and the shrinking platform are configured to uniformly sinter.

22 . The method of claim 21 , wherein the step of forming the part and the shrinking platform comprises forming tacks that penetrate the release layer therebetween the part and the shrinking platform.

23 . The method of claim 21 , wherein each of the part and the shrinking platform are configured to shrink at a same rate when sintered.

24 . The method of claim 21 , further comprising a step of forming a sliding release layer, comprising a material that powderizes when sintered, between a surface of the shrinking platform and a build plate opposing the surface.

25 . The method of claim 24 , wherein the step of forming the sliding release layer comprises forming tacks that penetrate the sliding release layer between the shrinking platform and the build plate.

26 . A method of additively manufacturing a three-dimensional structure, comprising steps of:
sintering a part and a shrinking platform, each of the part and the shrinking platform comprising metal particles and one or more binder components, at least a portion therebetween the part and the shrinking platform having a release layer, the release layer comprising a material that powderizes when the part and the shrinking platform are sintered; and wherein, during the sintering, the part and the shrinking platform are held in relative position with respect to one another.

27 . The method of claim of claim 26 , wherein each of the part and the shrinking platform are configured to shrink at a same rate during the sintering.

28 . A method of additively manufacturing a three-dimensional structure, comprising steps of:
forming a part, a support structure, and a shrinking platform, each of the part, the support structure, and the shrinking platform comprising metal particles and one or more binder components; forming a release layer between the support structure and the shrinking platform, the release layer comprising a material that powderizes when the part, the support structure, and the shrinking platform are sintered; and wherein, during sintering, the part and the support structure are held in relative position with respect to one another, and collectively, in relative position with respect to the shrinking platform.

29 . The method of claim 28 , wherein the step of forming the part, the support structure, and the shrinking platform comprises forming tacks that penetrate the release layer therebetween the support structure and the shrinking platform.

30 . The method of claim of claim 28 , wherein each of the part, the support structure, and the shrinking platform are configured to shrink at a same rate when sintered.

31 . The method of claim 28 , further comprising a step of forming a sliding release layer, comprising a material that powderizes when sintered, between a surface of the shrinking platform and a build plate opposing the surface.

32 . The method of claim 31 , wherein the step of forming the sliding release layer comprises forming tacks that penetrate the sliding release layer between the shrinking platform and the build plate.

33 . A method of additively manufacturing a three-dimensional structure, comprising steps of:
sintering a part, a support structure, and a shrinking platform, each of the part, the support structure and the shrinking platform comprising metal particles and one or more binder components, at least a portion therebetween the support structure and the shrinking platform having a release layer, comprising a material that powderizes when the part, the support structure, and the shrinking platform are sintered; and wherein, during the sintering, the part, the support structure, and the shrinking platform are held in relative position with respect to one another.

34 . The method of claim of claim 33 , wherein each of the part, the support structure, and the shrinking platform are configured to shrink at a same rate during the sintering.

35 . A method of additively manufacturing a three-dimensional structure, comprising steps of:
sintering a first body of model material and a second body of model material, the second body of model material configured as a shrinking platform, each of the first body of model material and the second body of model material comprising metal particles and one or more binder components, at least a portion therebetween the first body of model material and the second body of model material being a release layer, the release layer comprising a material that powderizes when the first body of model material and the second body of model material are sintered; and wherein, during sintering of the first body of model material and the second body of model material, the first body of model material and the second body of model material are configured to be held in relative position with respect to one another.

36 . The method of claim 35 , wherein the first body material comprises one or more parts.

37 . The method of claim 36 , further comprising a step of forming a release layer between layers of the first body of model material.

38 . The method of claim 37 , wherein the step of forming the release layer between layers of the first body of model material comprises forming tacks that penetrate the release layer between the layers of the first body of model material.

39 . The method of claim 35 , wherein the relative position is a common centroid.

40 . The method of claim 35 , wherein the release layer comprises a ceramic.

41 . The method of claim 35 , wherein the first body material comprises one or more support structures.

42 . The method of claim 41 , further comprising a step of forming a release layer between layers of the first body of model material.

43 . The method of claim 42 , wherein the step of forming the release layer between layers of the first body of model material comprises forming tacks that penetrate the release layer between the layers of the first body of model material.

Assignees

• Markforged Inc

Inventors

• Mark Gregory Thomas

Classifications

• B29C64/40 Primary

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• B29C64/209

  Heads; Nozzles · CPC title

• B22F3/1118

  comprising internal reinforcements · CPC title

• B29K2025/08

  Copolymers of styrene, e.g. AS or SAN, i.e. acrylonitrile styrene (B29K2055/02 takes precedence) · CPC title

• B29C64/245

  Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40) · CPC title