Method of additive manufacturing and method of making porous particles

Patent metadata

Field	Value
Publication number	US-2025058378-A1
Application number	US-202218719328-A
Country	US
Kind code	A1
Filing date	Dec 12, 2022
Priority date	Dec 22, 2021
Publication date	Feb 20, 2025
Grant date	—

Abstract

A method of additive manufacturing. The method comprises: i) positioning porous particles on a substrate, the porous particles having an average porosity and comprising at least one material chosen from metals and metalloids; ii) heating at least a portion of the porous particles to a reaction temperature; and iii) exposing the porous particles to a reactant gas to form a layer comprising a non-oxide ceramic. A method of making porous particles is also disclosed.

First claim

What is claimed is:

1 . A method of additive manufacturing, the method comprising:
i) positioning porous particles on a substrate, the porous particles having an average porosity and comprising at least one material chosen from metals and metalloids; ii) heating at least a portion of the porous particles to a reaction temperature; and iii) exposing the porous particles to a reactant gas to form a layer comprising a non-oxide ceramic.

2 . The method of claim 1 , further comprising, prior to i), determining a desired average porosity of porous particles, the desired average porosity of the porous particles resulting in: i) a desired porosity of a 3D printed product comprising a non-oxide ceramic made from the porous particles; or ii) a desired near-net shape of the 3D printed product.

3 . The method of claim 1 , wherein the non-oxide ceramic has a percent volume increase relative to the porous particles, the percent volume increase being about equal to the average porosity of the porous particles.

4 . The method of claim 1 , further comprising:
iv) positioning additional porous particles on the layer comprising the non-oxide ceramic, the additional porous particles having a second average porosity and comprising at least one material chosen from metals and metalloids; and v) heating the additional porous particles to the reaction temperature; and vi) exposing the additional porous particles to the reactant gas to form a second layer comprising the non-oxide ceramic; and vii) repeating iv) to vi) a plurality of times to form a 3D printed product on the substrate.

5 . The method of claim 4 , wherein the average porosity and the second average porosity are the same.

6 . The method of claim 4 , wherein the 3D printed product has a near-net shape.

7 . The method of claim 1 , wherein the average porosity ranges from about 10% to about 80%.

8 . The method of claim 1 , wherein the material is a metal or metalloid chosen from Ti, Hf, Ta, Zr, V, Nb, Cr, Mo, Co, Ni, Tc, Os, Re, W, Mn, Fe, Ga, Al, Si, B or alloys thereof.

9 . The method of claim 1 , wherein the reactant gas comprises at least one gas selected from a hydrocarbon, ammonia, nitrogen gas and boron hydrides.

10 . The method of claim 1 , wherein the non-oxide ceramic comprises at least one material selected from metal nitrides, metal carbides, metal borides, metalloid nitrides, metalloid carbides and metalloid borides.

11 . The method of claim 1 , wherein the method of additive manufacturing is selective laser reaction sintering.

12 . The method of claim 1 , wherein the substrate is the build plate of 3D printer.

13 . The method of claim 1 , wherein the porous particles do not include a polymer binder.

14 . A method of making porous particles, the method comprising:
determining the percent volume increase between a precursor material and a non-oxide ceramic formed from the precursor material; determining a desired average porosity of porous particles based on the percent volume increase; and forming porous particles comprising the precursor material and having the desired average porosity, the precursor material comprising at least one material chosen from metals and metalloids.

15 . The method of claim 14 , wherein the desired average porosity is chosen to be about the same as the percent volume increase.

16 . The method of claim 14 , wherein forming the porous particle comprises reduction of a metal compound chosen from metal hydrides, metal chlorides and metal oxides.

17 . The method of claim 14 , wherein forming the porous particle comprises aggregation of particles having a particle size ranging from about 10 nanometers to about 100 micrometers.

18 . The method of claim 14 , wherein forming the porous particle comprises dealloying.

Assignees

• Univ Johns Hopkins

Inventors

• Peters Adam B
• Zhang Dajie
• Chuang Alyssa
• Nagle Dennis

Classifications

• 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

• B22F10/28 Primary

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

• B33Y10/00

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• C04B2235/665

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