Binder jetting in additive manufacturing of inhomogeneous three-dimensional parts

Patent metadata

Field	Value
Publication number	US-2021331242-A1
Application number	US-201816328012-A
Country	US
Kind code	A1
Filing date	Oct 17, 2018
Priority date	Oct 17, 2017
Publication date	Oct 28, 2021
Grant date	—

Abstract

Devices, systems, and methods are directed to binder jetting for forming three-dimensional parts having controlled, macroscopically inhomogeneous material composition. In general, a binder may be delivered to each layer of a plurality of layers of a powder of inorganic particles. An active component may be introduced, in a spatially controlled distribution, to at least one of the plurality of layers such that the binder, the powder of inorganic particles, and the active component, in combination, form an object. The object may be thermally processed into a three-dimensional part having a gradient of one or more physicochemical properties of a material at least partially formed from thermally processing the inorganic particles and the active component of the object.

First claim

1 - 170 . (canceled)

171 . A method for forming an object, comprising:
depositing a first layer of powder along a powder bed, the depositing comprising spreading the layer of powder along the powder bed, the powder including inorganic particles; depositing, via a first printhead, a first layer of binder along a portion of the first layer of powder, the depositing comprising jetting via the first printhead, the first layer of binder along the first layer of powder; depositing, via a second printhead, an additive along the first layer of powder and the first layer of binder, the additive including an active component; forming, with the binder, layer of powder, and the active component, an object; and thermally processing the object into a three-dimensional part, the three-dimensional part including, in an area corresponding to a distribution of the active component of the object, a physicochemical gradient at least partially formed from thermally processing the inorganic particles and the active component of the object.

172 . The method of claim 171 , wherein the additive is selected from the group consisting of chromium, tungsten, manganese, nickel and molybdenum.

173 . The method of claim 171 , wherein the method further comprises, before the forming step:
depositing a second layer of powder along the powder bed; depositing, via the first printhead, a second layer of binder along the second layer of powder, the depositing comprising jetting via the first printhead, the first layer of binder along the first layer of powder; depositing, via the second printhead, the additive along the second layer of powder and the second layer of binder.

174 . The method of claim 171 , wherein the method further comprises placing the active component in a carrier.

175 . The method of claim 174 , wherein, upon being placed in the carrier, the active component remains undissolved and suspended in the carrier.

176 . The method of claim 174 , wherein the carrier includes a solvent selected from the group consisting of water, an aromatic organic substance, an aliphatic organic substance, alcohol, and a surfactant.

177 . The method of claim 176 , wherein the active component is dissolved in the solvent.

178 . The method of claim 171 , wherein the thermal processing further comprises chemically reacting the inorganic particles with one or more process gasses.

179 . The method of claim 171 , further comprising depositing a second layer of powder.

180 . The method of claim 171 , wherein the one or more binders are deposited to the plurality of layers of the powder between formation of successive layers of the plurality of layers of the powder.

181 . A method for delivering a plurality of fluids to form an object, comprising:
depositing a first layer of a plurality of layers of a powder along a powder bed, the powder including inorganic particles; jetting, via a first printhead, a first layer of binder along a portion of the first layer of the powder; jetting, via a second printhead, an additive along the first layer of the powder; forming, with the binder, the layer of powder, and the additive, an object; and thermally processing the object into a three-dimensional part, the three-dimensional part including, in an area corresponding to a distribution of the additive of the object, a physicochemical gradient at least partially formed from thermally processing the inorganic particles and the additive of the object.

182 . The method of claim 181 , wherein the additive is selected from the group consisting of an active component, a salt, and a first polymer and an active component attached to the first polymer.

183 . The method of claim 181 , wherein the additive comprises an ink, the ink chemically modifying the binder to form an active component.

184 . The method of claim 181 , wherein the inorganic particles include at least one of ceramic particles or metallic particles.

185 . The method of claim 181 , wherein the one or more binders include at least one of a polymer, a salt, nanoparticles, or a gel.

186 . The method of claim 181 , wherein the first layer of binder include a first binder, the additive further comprising a second binder different from the first binder.

187 . The method of claim 181 , wherein the additive includes one or more of carbon black, graphene, carbon nanotubes, boron or silicon carbide.

188 . A method for increasing corrosion resistance while delivering a plurality of fluids to form an object, comprising:
depositing a plurality of layers of a powder along a powder bed, the powder including inorganic particles; depositing one or more binders along a portion of the plurality of layers of the powder, the depositing comprising jetting, via a first printhead, the one or more binders onto the plurality of layers of powder; depositing, via a second printhead, an additive along one or more of the plurality of layers, the additive including an active component, the active component being formed in the additive in a higher volumetric concentration than in each of the one or more binders and providing corrosion resistance; forming, with the one or more binders, the plurality of layers, and the active component, an object; and thermally processing the object into a three-dimensional part, the three-dimensional part including, in an area corresponding to a distribution of the active component of the object, a physicochemical gradient at least partially formed from thermally processing the inorganic particles and the active component of the object.

189 . The method of claim 188 , wherein the inorganic particles include at least one of ceramic particles or metallic particles.

190 . The method of claim 188 , wherein the one or more binders include at least one of a polymer, a salt, nanoparticles, or a gel.

191 . The method of claim 188 , wherein the active layer is formed of one of chromium, molybdenum, and nickel.

Assignees

• Desktop Metal Inc

Inventors

• Barbati Alexander
• Gibson Michael Andrew
• Tuncer Nihan
• Kernan Brian

Classifications

• B22F10/30

  Process control · CPC title

• B22F12/33

  translatory in the deposition plane · CPC title

• B22F1/10

  Metallic powder containing lubricating or binding agents; Metallic powder containing organic material · CPC title

• C04B35/111 Primary

  Fine ceramics · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title