Managing powder mobility in binder jetting for additive manufacturing

Patent metadata

Field	Value
Publication number	US-2023150193-A1
Application number	US-202217956207-A
Country	US
Kind code	A1
Filing date	Sep 29, 2022
Priority date	Jan 9, 2018
Publication date	May 18, 2023
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 . A method of forming an object using binder jet additive manufacturing, the method comprising:
forming a layer of powder within a build chamber; generating a first fluid in a vapor phase; adjusting or maintaining an environment within the build chamber to affect a condensation of the first fluid from the vapor phase to a liquid phase; and condensing the first fluid from the vapor phase to the liquid phase on at least a portion of the layer of powder.

2 . The method of claim 1 , wherein adjusting or maintaining the environment within the build chamber includes controlling a temperature of at least a portion of the layer of powder to below a dew point of the first fluid in the vapor phase.

Assignees

• Desktop Metal Inc

Inventors

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

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B22F12/63

  Rollers · CPC title

• B22F12/10

  Auxiliary heating means · 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