Source: https://patents.google.com/patent/US10000011B1/en
Timestamp: 2019-01-24 09:43:02
Document Index: 112092240

Matched Legal Cases: ['§ 119', 'art 14', 'art 14', 'art 14', 'art 14', 'art.\n22']

US10000011B1 - Supports for sintering additively manufactured parts - Google Patents
Supports for sintering additively manufactured parts Download PDF
US10000011B1
US10000011B1 US15722445 US201715722445A US10000011B1 US 10000011 B1 US10000011 B1 US 10000011B1 US 15722445 US15722445 US 15722445 US 201715722445 A US201715722445 A US 201715722445A US 10000011 B1 US10000011 B1 US 10000011B1
desired part
US15722445
This application claims the benefit under 35 U.S.C. § 119(e) of U.S. provisional application Ser. No. 62/429,711, filed Dec. 2, 2016, entitled “SUPPORTS FOR SINTERING ADDITIVELY MANUFACTURED PARTS”; 62/430,902, filed Dec. 6, 2016, entitled “WARM SPOOL FEEDING FOR SINTERING ADDITIVELY MANUFACTURED PARTS”; 62/442,395 filed Jan. 4, 2017, entitled “INTEGRATED DEPOSITION AND DEBINDING OF ADDITIVE LAYERS OF SINTER-READY PARTS”; 62/480,331 filed Mar. 31, 2017, entitled “SINTERING ADDITIVELY MANUFACTURED PARTS IN A FLUIDIZED BED”; 62/489,410 filed Apr. 24, 2017, entitled “SINTERING ADDITIVELY MANUFACTURED PARTS IN MICROWAVE OVEN”; 62/505,081 filed May 11, 2017, entitled “RAPID DEBINDING VIA INTERNAL FLUID CHANNELS”; 62/519,138 filed Jun. 13, 2017, entitled “COMPENSATING FOR BINDER-INTERNAL STRESSES IN SINTERABLE 3D PRINTED PARTS”; and 62/545,966 filed Aug. 15, 2017, entitled “BUBBLE REMEDIATION IN 3D PRINTING OF METAL POWDER IN SOLUBLE BINDER FEEDSTOCK”, the disclosures of which are herein incorporated by reference in their entireties.
The printer(s) of FIGS. 1-9, with at least two print heads 18, 10 and/or printing techniques, deposit with one head a composite material including a debinder and dispersed spheres or powder 18 (thermoplastic or curing), used for printing both a part and support structures, and with a second head 18 a (shown in FIGS. 4-9) deposits release or separation material. Optionally a third head and/or fourth head include a green body support head 18 b and/or a continuous fiber deposition head 10. A fiber reinforced composite filament 2 (also referred to herein as continuous core reinforced filament) may be substantially void free and include a polymer or resin that coats, permeates or impregnates an internal continuous single core or multistrand core. It should be noted that although the print head 18, 18 a, 18 b are shown as extrusion print heads, “fill material print head” 18, 18 a, 18 b as used herein may include optical or UV curing, heat fusion or sintering, or “polyjet”, liquid, colloid, suspension or powder jetting devices—not shown—for depositing fill material, so long as the other functional requirements described herein are met (e.g., green body material supports printing vs. gravity or printing forces, sintering or shrinking supports the part vs. gravity and promote uniform shrinking via atomic diffusion during sintering, and release or separation materials substantially retain shape through debinding stems but become readily removable, dispersed, powderized or the like after sintering).
A fiber reinforced composite filament, when used, is fed, dragged, and/or pulled through a conduit nozzle optionally heated to a controlled temperature selected for the matrix material to maintain a predetermined viscosity, force of adhesion of bonded ranks, melting properties, and/or surface finish. After the matrix material or polymer of the fiber reinforced filament is substantially melted, the continuous core reinforced filament is applied onto a build platen 16 to build successive layers of a part 14 to form a three dimensional structure. The relative position and/or orientation of the build platen 16 and print heads 18, 18 a, 18 b, and/or 10 are controlled by a controller 20 to deposit each material described herein in the desired location and direction. A driven roller set 42, 40 may drive a continuous filament along a clearance fit zone that prevents buckling of filament. In a threading or stitching process, the melted matrix material and the axial fiber strands of the filament may be pressed into the part and/or into the swaths below, at times with axial compression. As the build platen 16 and print head(s) are translated with respect to one another, the end of the filament contacts an ironing lip and be subsequently continually ironed in a transverse pressure zone to form bonded ranks or composite swaths in the part 14.
With reference to FIG. 1, each of the printheads 18, 18 a, 18 b, 10 may be mounted on the same linear guide or different linear guides or actuators such that the X, Y motorized mechanism of the printer moves them in unison. As shown, each extrusion printhead 18, 18 a, 18 b may include an extrusion nozzle with melt zone or melt reservoir, a heater, a high thermal gradient zone formed by a thermal resistor or spacer (optionally an air gap), and/or a Teflon or PTFE tube. A 1.75-1.8 mm; 3 mm; or larger or smaller thermoplastic filament is driven through, e.g., direct drive or a Bowden tube provides extrusion back pressure in the melt reservoir.
FIG. 2 depicts a block diagram and control system of the three dimensional printer which controls the mechanisms, sensors, and actuators therein, and executes instructions to perform the control profiles depicted in and processes described herein. A printer is depicted in schematic form to show possible configurations of e.g., three commanded motors 116, 118, and 120. It should be noted that this printer may include a compound assembly of printheads 18, 18 a, 18 b, and/or 10.
As depicted in FIG. 2, the three-dimensional printer 3001 includes a controller 20 which is operatively connected to the fiber head heater 715, the fiber filament drive 42 and the plurality of actuators 116, 118, 120, wherein the controller 20 executes instructions which cause the filament drive to deposit and/or compress fiber into the part. The instructions are held in flash memory and executed in RAM (not shown; may be embedded in the controller 20). An actuator 114 for applying a spray coat, as discussed herein, may also be connected to the controller 20. In addition to the fiber drive 42, respective filament feeds 1830 (e.g., up to one each for heads 18, 18 a, and/or 18 b) may be controlled by the controller 20 to supply the extrusion printhead 1800. A printhead board 110, optionally mounted on the compound printhead and moving therewith and connected to the main controller 20 via ribbon cable, breaks out certain inputs and outputs. The temperature of the ironing tip 726 may be monitored by the controller 20 by a thermistor or thermocouple 102; and the temperature of the heater block holding nozzle 1802 of any companion extrusion printhead 1800 may be measured by respective thermistors or thermocouples 1832. A heater 715 for heating the ironing tip 726 and respective heater 1806 for heating respective extrusion nozzles 1802 are controlled by the controller 20. Heat sink fan(s) 106 and a part fan(s) 108, each for cooling, may be shared between the printheads, or independently provided, and controlled by the controller 20. A rangefinder 15 is also monitored by the controller 20. The cutter 8 actuator, which may be a servomotor, a solenoid, or equivalent, is also operatively connected. A lifter motor for lifting one or any printhead away from the part (e.g., to control dripping, scraping, or rubbing) may also be controlled. Limit switches 112 for detecting when the actuators 116, 118, 120 have reached the end of their proper travel range are also monitored by the controller 20.
FIG. 3 depicts a flowchart showing a printing operation of the printers 1000 in FIGS. 1-9. FIG. 3 describes, as a coupled functionality, control routines that may be carried out to alternately and in combination use the co-mounted FFF extrusion head(s) 18, 18 a, and/or 18 b and a fiber reinforced filament printing head as in the CFF patent applications.
In FIG. 3, at the initiation of printing, the controller 20 determines in step S10 whether the next segment to be printed is a fiber segment or not, and routes the process to S12 in the case of a fiber filament segment to be printed and to step S14 in the case of other segments, including e.g., base, fill, or coatings. After each or either of routines S12 and S14 have completed a segment, the routine of FIG. 3 checks for slice completion at step S16, and if segments remain within the slice, increments to the next planned segment and continues the determination and printing of fiber segments and/or non-fiber segments at step S18. Similarly, after slice completion at step S16, if slices remain at step S20, the routine increments at step S22 to the next planned slice and continues the determination and printing of fiber segments and/or non-fiber segments. “Segment” as used herein corresponds to “toolpath” and “trajectory”, and means a linear row, road, or rank having a beginning and an end, which may be open or closed, a line, a loop, curved, straight, etc. A segment begins when a printhead begins a continuous deposit of material, and terminates when the printhead stops depositing. A “slice” is a single layer or lamina to be printed in the 3D printer, and a slice may include one segment, many segments, lattice fill of cells, different materials, and/or a combination of fiber-embedded filament segments and pure polymer segments. A “part” includes a plurality of slices to build up the part. FIG. 3's control routine permits dual-mode printing with one, two, or more (e.g., four) different printheads, including the compound printheads 18, 18 a, 18 b, and/or 10.
All of the printed structures previously discussed may be embedded within a printed article during a printing process, as discussed herein, expressly including reinforced fiber structures of any kind, sparse, dense, concentric, quasi-isotropic or otherwise as well as fill material or plain resin structures. In addition, in all cases discussed with respect to embedding in a part, structures printed by fill material heads 18, 18 a, 18 b using thermoplastic extrusion deposition may be in each case replaced with soluble material (e.g., soluble thermoplastic or salt) to form a soluble preform which may form a printing substrate for part printing and then removed. All continuous fiber structures discussed herein, e.g., sandwich panels, shells, walls, reinforcement surrounding holes or features, etc., may be part of a continuous fiber reinforced part.
With reference to FIGS. 1 and 2, each of the printheads 18 and 10 are mounted on the same linear guide such that the X, Y motorized mechanism 116, 118 of the printer 1000 moves them in unison. A 1.75-1.8 mm; 3 mm or larger or smaller metal filament 10 b may be driven through, e.g., direct drive or a Bowden tube that may provide extrusion back pressure in a melt reservoir 10 a or crucible.
FIG. 6 shows a variation of the 3D printer, printing method, part structure, and materials of FIG. 4. In FIG. 6, no separate green body support deposition head 18 c is provided. Accordingly, green body supports and separation layers are formed from the same material—e.g., the composite material used for separation layers, in which a ceramic or high-temperature metal particles or spheres are distributed in an, e.g., two-stage debindable matrix. In this case, the green body supports are not necessarily removed during or before debinding or in a separate process, but are instead simply weakened during debinding and, as with the separation layers, have their remaining polymer material pyrolized during sintering. The remaining ceramic powder can be cleaned out and/or removed following sintering, at the same time as the separation layers.
As shown in FIG. 8, in contrast to the sintering supports SS1 of FIGS. 4 and 6, sintering (e.g., shrinking) supports SS2, supporting overhangs OH2 and OH3, may be formed including thin walled, vertical members. The vertical members of sintering supports SS2 may be independent (e.g., vertical rods or plates) or interlocked (e.g., accordion or mesh structures). As shown in FIG. 8, the sintering supports SS2 (or indeed the sintering supports SS1 of FIGS. 4 and 6, or the sintering supports SS3, SS4, and SS5 of FIG. 8) may be directly tacked (e.g., contiguously printed in model material, but with relatively small cross-sectional area) to a raft RA2, to the part 14 a, and/or to each other. Conversely, the sintering supports SS2 may be printed above, below, or beside a separation layer, without tacking. As shown, the sintering supports SS2 are removable from the orthogonal, concave surfaces of the part 14 a.
Secondary Elastic Modulus Elastic Modulus
matrix (109 N/m2, GPa) Fill (109 N/m2, GPa)
Steel 180-200 Carbon Fiber 200-600
Aluminum 69 Graphite Fiber 200-600
Copper 117 Boron Nitride 100-400
Titanium 110 Boron Carbide 450
Alumina 215 Silicon Carbide 450
Cobalt 209 Alumina 215
Bronze 96-120 Diamond 1220
Carbon Nanotube 1000+
forming a shrinking platform of successive layers of composite, the composite including a metal particulate filler in a debindable matrix;
forming shrinking supports of the composite above the shrinking platform;
forming a desired part of the composite upon the shrinking platform and shrinking supports, all portions of the desired part being vertically and directly supported by the shrinking platform;
forming a sliding release layer below the shrinking platform of equal or larger surface area than a bottom of the shrinking platform that reduces lateral resistance between the shrinking platform and an underlying surface;
debinding the matrix sufficient to form a shape-retaining brown part assembly including the shrinking platform, the shrinking supports, and the desired part; and
heating the shape-retaining brown part assembly formed from the composite to shrink all of the shrinking platform, the shrinking supports, and the desired part together at a same rate as neighboring metal particles throughout the shape-retaining brown part assembly undergo mass diffusion.
depositing an open cell structure including interconnections among cell chambers in at least one of the shrinking platform, the shrinking supports, and the desired part; and
penetrating a fluid debinder into the open cell structure to debind the matrix from within the open cell structure.
forming a lateral support shell of the composite following a lateral contour of the desired part; and
connecting the lateral support shell to the lateral contour of the desired part by forming separable attachment protrusions of the composite between the lateral support shell and the desired part.
forming soluble support structures of the debindable matrix without the metal particulate filler that resist downward forces during the forming of the desired part; and
debinding the matrix sufficient to dissolve the soluble support structures before heating the shape-retaining brown part assembly.
forming soluble support structures of a release composite, the release composite including a ceramic particulate filler, the debindable matrix and less than a sinterable amount of the metal particulate filler, the soluble support structures resisting downward forces during the forming of the desired part; and
before heating the shape-retaining brown part assembly, debinding the matrix sufficient to form a shape-retaining brown part assembly including the shrinking platform, shrinking supports, and desired part and to dissolve the matrix of the soluble support structures.
8. The method according to claim 1, wherein the underlying surface comprises a portable build plate, and wherein the method further comprises:
forming the shrinking platform above the portable build plate;
forming the sliding release layer below the shrinking platform and above the portable build plate with a release composite including a ceramic particulate and the debindable matrix;
sintering the shape-retaining brown part assembly during the heating;
keeping the build plate, sliding release layer, and shape-retaining brown part assembly together as a unit during the debinding and during the sintering;
after sintering, separating the build plate, sliding release layer, shrinking platform, and shrinking supports from the desired part.
forming part release layers between the shrinking supports and the desired part with a release composite including a ceramic particulate filler and the debindable matrix;
keeping the part release layers and shape-retaining brown part assembly together as a unit during the debinding and during the sintering;
depositing an open cell structure including interconnections among cell chambers in the shrinking supports; and
depositing, in successive layers, a shrinking platform formed from a composite, the composite including a metal particulate filler in a debindable matrix;
depositing shrinking supports of the composite above the shrinking platform;
depositing an open cell structure including interconnections among cell chambers in the shrinking supports;
depositing, from the composite, a desired part upon the shrinking platform and shrinking supports;
exposing the shrinking platform, shrinking supports, and desired part to a fluid debinder to form a shape-retaining brown part assembly;
penetrating the fluid debinder into the open cell structure to debind the matrix from within the open cell structure; and
sintering the shape-retaining brown part assembly to shrink at a rate common throughout the shape-retaining brown part assembly.
depositing part release layers between the shrinking supports and the desired part with a release composite including a ceramic particulate filler and the debindable matrix;
keeping the part release layers and shape-retaining brown part assembly together as a unit during the exposing and during the sintering;
forming vertical gaps without release composite between shrinking supports and the desired part where a vertical surface of a shrinking support opposes an adjacent wall of the desired part.
depositing at least one of the shrinking platform, the lateral support shell, and the desired part with interconnections between internal chambers; and
penetrating a fluid debinder via the interconnections into the internal chambers to debind the matrix from within the open cell structure.
forming, among the shrinking supports, parting lines as separation clearances dividing the shrinking supports into fragments separable along the separation clearances;
shaping, from the composite, a desired part upon the shrinking platform and shrinking supports,
debinding the matrix sufficient to form a shape-retaining brown part assembly including the shrinking platform, shrinking supports, and desired part;
sintering the shape-retaining brown part assembly to shrink at a rate uniform throughout the shape-retaining brown part assembly;
separating the shrinking supports into fragments along the separation clearances; and
separating the fragments from the desired part.
22. The method according to claim 21, wherein one or more of the separation clearances are formed as vertical clearance separating neighboring shrinking supports and extend for substantially a height of the neighboring shrinking supports, and further comprising:
separating the neighboring shrinking supports from one another along the vertical clearances.
forming, within a cavity of the desired part, interior shrinking supports from the composite;
forming, among the interior shrinking supports, parting lines as separation clearances dividing the interior shrinking supports into subsection fragments separable along the separation clearances; and
separating the subsection fragments from one another along the separation clearances.
forming a lateral support shell of the composite as the shrinking supports to follow a lateral contour of the desired part; and
forming, in the lateral support shell, parting lines dividing the lateral support shell into shell fragments separable along the parting lines;
debinding the matrix sufficient to form a shape-retaining brown part assembly including the shrinking platform, shrinking supports, lateral support shell, and desired part;
separating the lateral support shell into the shell fragments along the parting lines; and
separating the shell fragments from the desired part.
depositing at least one of the shrinking platform, the shrinking supports, and the desired part with interconnections between internal chambers; and
debinding the matrix sufficient to dissolve the soluble support structures before sintering the shape-retaining brown part assembly.
forming a sliding release layer below the shrinking platform of equal or larger surface area than a bottom of the shrinking platform that reduces lateral resistance between the shrinking platform and build plate
forming the sliding release layer below the shrinking platform and above the portable build plate with a release composite including a ceramic particulate and the debindable matrix; and
keeping the build plate, sliding release layers and shape-retaining brown part assembly together as a unit during the debinding and during the sintering.
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