Patent Description:
The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments of the present invention, which is defined by the claims.

Reference will now be made in detail to certain embodiments of the disclosed subject matter, examples of which are illustrated in part in the accompanying drawings.

<FIG> are profile and overhead views of a first continuous single layer manufacturing device <NUM>. <FIG> shows a profile view of the first continuous single layer manufacturing device <NUM>. Manufacturing device <NUM> includes a binder hopper <NUM> for dispensing a binder precursor onto a wheel substrate <NUM>. The binder precursor may include a resin binder, a ceramic binder, or a metal binder. The binder hopper <NUM> may also dispense grinding aids, pore formers, secondary grains, fillers, or other materials. In some embodiments, the binder precursor may be distributed using a continuous band (e.g., tape) of plasticized resin (not shown), such as described in <CIT>. Reinforcement materials may also be dispensed by the binder hopper <NUM> or by another device (not shown), where the reinforcement materials may include chopped fibers, partial scrim, full scrims, or other reinforcement materials. Manufacturing device <NUM> may include an abrasive dispenser <NUM> for dispensing an abrasive onto the wheel substrate <NUM>. The dispensed abrasive may include precision shaped minerals, elongated crushed abrasive, extruded abrasive, vitrified agglomerates, resin bond agglomerates, crushed abrasive, or other abrasive. The abrasive dispenser <NUM> may be used to place the abrasive at predetermined positions or in predetermined orientations within specific circular segments of the wheel substrate, such as shown in <FIG>.

<FIG> shows an overhead view of the first continuous single layer manufacturing device <NUM>. The binder hopper <NUM> shown in <FIG> may dispense the binder precursor onto a binder circular section <NUM> of the wheel substrate <NUM>. Manufacturing device <NUM> may include a leveling device <NUM>, which may be used to level and distribute the binder precursor <NUM> across the radius of the wheel substrate <NUM>. The leveling device <NUM> may include a leveling blade, a leveling fork, or other leveling structure. The abrasive dispenser <NUM> shown in <FIG> may dispense the abrasive onto an abrasive circular section <NUM> of the wheel substrate <NUM>. A recess pressing device (not shown) may be used to push recesses into the leveled binder precursor, and the recesses may be used to receive the dispensed abrasive. An abrasive pressing device (not shown) may be used to press the dispensed abrasive into the leveled binder precursor.

The wheel substrate <NUM> may rotate while the binder precursor and abrasive are dispensed. For example, the wheel substrate <NUM> show in <FIG> may be rotated counterclockwise, such that additional binder is dispensed over the abrasive on subsequent rotations, the additional binder is leveled, and additional abrasive is placed on the additional binder. This process may continue, forming a continuous spiral layer of binder and abrasive particles. In an example, wheel substrate <NUM> may include an inclined wheel substrate rotating around a vertical central bore axis <NUM>, where the inclined wheel plane may be offset from a horizontal plane relative to the vertical central bore axis <NUM> to aid in formation of the spiral layer of binder and abrasive particles. In another example, the wheel substrate <NUM> includes an initial deposit of binder, wherein the initial binder deposit provides an initial ramp to aid in formation of the spiral layer of binder and abrasive particles. The spiraling building of abrasive articles on the inclined wheel may be used to form a cylindrical body that includes a continuous spiral-shaped abrasive layer.

The spiral layers of binder and abrasive particles may be pressed or cured following deposition of all spiral layers, or each layer may be cured as the wheel substrate <NUM> rotates. The curing may include temporary (e.g., intermediate) curing or final curing, and may include infrared (IR) heating, ultraviolet (UV) curing, microwave curing, use of two-component curing materials (e.g., hardening as a function of time), or other curing materials. While <FIG> shows the binder circular section <NUM> opposite from the abrasive circular section <NUM> of the wheel substrate <NUM>, other configurations may be used. For example, the binder circular section <NUM> and the abrasive circular section <NUM> may be on a first half of the wheel substrate <NUM>, the wheel may be rotated <NUM>°, and the dispensing process repeated.

<FIG> are profile and overhead views of a second continuous single layer manufacturing device. <FIG> shows a profile view of the second continuous single layer manufacturing device <NUM>. Manufacturing device <NUM> includes a binder hopper <NUM> for dispensing a binder precursor onto a wheel substrate <NUM>. Manufacturing device <NUM> may also include an abrasive hopper <NUM> for dispensing an abrasive onto the wheel substrate <NUM>. The abrasive hopper <NUM> may include a very narrow gap across the radius of the wheel substrate <NUM> to dispense a continuous monolayer of abrasive material.

<FIG> shows an overhead view of the second continuous single layer manufacturing device <NUM>. The binder hopper <NUM> shown in <FIG> may dispense the binder precursor onto a binder circular section <NUM> of the wheel substrate <NUM>. Leveling device <NUM> may be used to level and distribute the binder precursor <NUM> across the radius of the wheel substrate <NUM>. The abrasive dispenser <NUM> shown in <FIG> may dispense the abrasive onto an abrasive circular section <NUM> of the wheel substrate <NUM>. A sectional mask may be used below binder hoper <NUM> or abrasive hoper <NUM> to aid in placement of the binder or mineral in their respective binder circular section <NUM> and abrasive circular section <NUM>.

<FIG> is a perspective view of a binder leveling device <NUM>. Binder leveling device <NUM> may include a wheel mold <NUM> into which binder <NUM> is deposited. The binder may be deposited into the wheel mold <NUM> using one or more hoppers or placement devices. In an embodiment, an abrasive mixture is deposited, where the abrasive mixture includes both binder and abrasive. The abrasive mixture may further include grinding aids, pore formers, fillers, reinforcement materials, or other materials. In an embodiment, the abrasive may be placed in predetermined positions or predetermined orientations subsequent to leveling, such as by an abrasive placement device (not shown).

A leveler <NUM> may be used to level the binder. While the leveler <NUM> shown in <FIG> includes a blade leveler, a fork or other leveling device may be used. The leveler <NUM> may be used to adjust the density of the binder or abrasive, such as by modifying the mounting angle of a leveling blade. The density or composition of the binder or abrasive may be modified by using one or more hoppers or placement devices to modify the number of binder or abrasive particles per unit area. The density or composition of the binder or abrasive may be modified by using multiple hoppers or placement devices to deposit different types of binders or abrasives. The density or composition of the binder or abrasive may be selected to provide uniform removal of the material to be ground by the grinding wheel. In an embodiment, a first binder and abrasive are deposited in a first region of the wheel mold <NUM>, and a second binder and abrasive are deposited in a second region of the wheel mold <NUM>. The use of two or more regions of binder or abrasive may be useful in providing regions with different properties, such as differing abrasive regions for face-grinding or edge-grinding applications. Once the wheel mold <NUM> is filled and leveled to form a continuous spiral abrasive layer of binder and abrasive particles, the resulting spiral abrasive layer may be pressed and cured. Scrims may be placed on the inside or outside of the continuous spiral abrasive layer to provide additional reinforcement.

<FIG> are sectional views of a continuous single layer manufacturing abrasive article <NUM>. <FIG> shows a vertically cut spiral cross-section of the continuous spiral abrasive layer, and <FIG> shows a horizontally cut spiral cross-section. The cross-section may include binder <NUM> and abrasive <NUM>. The continuous spiral abrasive layer provides various advantages, including providing abrasive <NUM> that are uncovered at varying times during the lifetime of the abrasive wheel. For example, in contrast with a horizontal layer that may include minimal abrasive at the boundary of each layer, the continuous spiral abrasive layer would expose different portions of each abrasive <NUM> as the wheel is ground away.

<FIG> shows an example placement of the abrasive <NUM>. The abrasive <NUM> may be placed using various techniques. The abrasive may be placed into predetermined locations or in predetermined orientations using an abrasive placement device (e.g., a "pick- and-place" device). The orientation of the abrasive may be selected or modified by coating the abrasive with a magnetically responsive coating or by placing such magnetically responsive particles inside an agglomerate. A magnetic field may be used to orient the mineral or agglomerate in the desired direction. The abrasive may be blended into the binder precursor material and subsequently oriented using magnets or other magnetic field, such as by using a plurality of magnets placed near the outer circumference or upper surface of the wheel. Magnetically responsive materials and abrasive placement devices are described further below. The abrasive may be placed in a predetermined pattern on a carrier film and deposited onto the leveled binder precursor surface. The abrasive may be affixed in a predetermined pattern on a carrier structure placed within the leveled binder precursor, such as the spiral carrier structure shown in <FIG>.

<FIG> is perspective diagram showing a spiral abrasive placement substrate article <NUM>. The spiral abrasive placement substrate article <NUM> may include a helical abrasive substrate <NUM> to aid in orientation and placement of abrasive particles. The helical abrasive substrate <NUM> may include a plurality of abrasive particles in predetermined orientations or preterminal positions, and helical abrasive substrate <NUM> may be placed on the leveled binder during formation of the continuous spiral abrasive layer. For example, the helical abrasive substrate <NUM> may include a spirally oriented abrasive <NUM>, where the spirally oriented abrasive <NUM> is oriented substantially in the circular cutting direction of the wheel (e.g., perpendicular to the radius), such as for cylindrical grinding applications. The helical abrasive substrate <NUM> may include a vertically oriented abrasive <NUM>, where the vertically oriented abrasive <NUM> may be oriented substantially upward or downward relative to the helical abrasive substrate <NUM>, such as for face-grinding applications. Though the vertically oriented abrasive <NUM> include abrasive plates oriented perpendicular to the radius, vertical abrasive plates may be oriented parallel or in other orientations relative to the radius. The helical abrasive substrate <NUM> may include a radially oriented abrasive <NUM>, where the radially oriented abrasive <NUM> may be oriented substantially parallel to the radius, such as for cylindrical grinding or cutting wheel applications.

The helical substrate <NUM> may include one or more helical strands, such as a double helix or other helical structure. Abrasive particles may be affixed to one or more surfaces of the helical substrate <NUM>, such as including vertical abrasive <NUM> on both the upper and lower surfaces of the helical substrate <NUM>. The helical substrate <NUM> may include a thin substrate to reduce or minimize the volume of the substrate, and may include a sacrificial tape, a functional mesh (e.g., fiber mesh, ceramic mesh, metal mesh, paper mesh), or other thin substrate. The helical substrate <NUM> may include a circular horizontal cross-section as shown in <FIG>, or may include a star-shaped horizontal cross-section, an oscillating (e.g., wavy) circular horizontal cross-section shown in <FIG>, or other horizontal cross-section shape.

<FIG> are perspective diagrams showing a wavy spiral abrasive placement substrate article. The spiral abrasive placement substrate article <NUM> may include a wavy helical abrasive substrate <NUM> to aid in orientation and placement of abrasive particles. The wavy helical abrasive substrate <NUM> may include a plurality of abrasive particles in predetermined orientations or preterminal positions, and wavy helical abrasive substrate <NUM> may be placed on the leveled binder during formation of the continuous spiral abrasive layer. For example, the wavy helical abrasive substrate <NUM> may include a spirally oriented abrasive <NUM>, where the spirally oriented abrasive <NUM> is oriented substantially in the circular cutting direction of the wheel (e.g., perpendicular to the radius), such as for cylindrical grinding applications. The wavy helical abrasive substrate <NUM> may include a vertically oriented abrasive <NUM>, where the vertically oriented abrasive <NUM> may be oriented substantially upward or downward relative to the wavy helical abrasive substrate <NUM>, such as for face-grinding applications. Though the vertically oriented abrasive <NUM> include abrasive plates oriented perpendicular to the radius, vertical abrasive plates may be oriented parallel or in other orientations relative to the radius. The wavy helical abrasive substrate <NUM> may include a radially oriented abrasive <NUM>, where the radially oriented abrasive <NUM> may be oriented substantially parallel to the radius, such as for cylindrical grinding or cutting wheel applications. The wavy helical substrate <NUM> may include one or more helical strands, such as a double helix or other helical structure. Abrasive particles may be affixed to one or more surfaces of the wavy helical substrate <NUM>, such as including vertical abrasive <NUM> on both the upper and lower surfaces of the helical substrate <NUM>. The wavy helical substrate <NUM> may include a thin substrate to reduce or minimize the volume of the substrate, and may include a sacrificial tape, a functional mesh (e.g., fiber mesh, ceramic mesh, metal mesh, paper mesh), or other thin substrate.

In creating the part layer by layer, one of the challenges is the time needed to build each layer, reducing the range of potential products that are cost effective.

Described herein is a 3D-printing continuous process, where all the steps are done together at the same time. This can reduce the layer building time by more than half and increase the throughput of the printer. Additionally, several parts can be made simultaneously on the same workspace, further reducing a per-part time to manufacture. While the discussion below focusses on powder bed binder jetting, other additive manufacturing techniques, such as powder bed fusion, may also be implemented using systems and methods described herein.

Powder bed binder jetting is a process where a thin layer of a powder is spread out evenly and then is partially bonded at desired locations by a liquid binder mixture. Typically, that binder mixture is dispensed by an inkjet print head and consists of a polymer dissolved in a suitable solvent or carrier solution. The role of the binder is to fix each particle in place, keeping the homogeneity of the mixture and forming the expected shape of the final article in a layer-by-layer process. The first layer then is at least partially dried and lowered so that a next powder layer is spread. The powder spreading, layer levelling, bonding and setting processes can be repeated until the full object is created. These <NUM> steps are usually done sequentially for a given abrasive layer.

The abrasive article precursor and surrounding powder is removed from the printer and often dried or cured to impart additional strength so that the now hardened object can be extracted from the surrounding powder.

In some cases, the powder in the object can be in a matrix form so that another material can be infused or infiltrated in a subsequent step to create a fully dense obj ect.

The time needed for each different step is highly dependent on the abrasive mixture being printed. A highly flowable powder can be spread and levelled much faster than a mixture having a poor flowability behavior. A highly conductive powder can be heated and dried faster than a refractory or ceramic material. Printing time is usually driven by the abrasive mixture but also by the precision needed for the final abrasive product. The precision needed determines the thickness possible for each abrasive layer. Printing time can also increase depending on the needed strength to handle the printed part before a final consolidation step.

As used herein "shaped abrasive particle" means an abrasive particle having a predetermined or non-random shape. One process to make a shaped abrasive particle such as a shaped ceramic abrasive particle includes shaping the precursor ceramic abrasive particle in a mold having a predetermined shape to make ceramic shaped abrasive particles. Ceramic shaped abrasive particles, formed in a mold, are one species in the genus of shaped ceramic abrasive particles. Other processes to make other species of shaped ceramic abrasive particles include extruding the precursor ceramic abrasive particle through an orifice having a predetermined shape, printing the precursor ceramic abrasive particle though an opening in a printing screen having a predetermined shape, or embossing the precursor ceramic abrasive particle into a predetermined shape or pattern. In other examples, the shaped ceramic abrasive particles can be cut from a sheet into individual particles. Examples of suitable cutting methods include mechanical cutting, laser cutting, or water-jet cutting. Non-limiting examples of shaped ceramic abrasive particles include shaped abrasive particles, such as triangular plates, tetrahedral abrasive particles, elongated ceramic rods/filaments, or other shaped abrasive particles. Shaped ceramic abrasive particles are generally homogenous or substantially uniform and maintain their sintered shape without the use of a binder such as an organic or inorganic binder that bonds smaller abrasive particles into an agglomerated structure and excludes abrasive particles obtained by a crushing or comminution process that produces abrasive particles of random size and shape. In many embodiments, the shaped ceramic abrasive particles comprise a homogeneous structure of sintered alpha alumina or consist essentially of sintered alpha alumina. Any of shaped abrasive particles can include any number of shape features. The shape features can help to improve the cutting performance of any of shaped abrasive particles. Examples of suitable shape features include an opening, a concave surface, a convex surface, a groove, a ridge, a fractured surface, a low roundness factor, or a perimeter comprising one or more corner points having a sharp tip. Individual shaped abrasive particles can include any one or more of these features.

The abrasive may include conventional (e.g., crushed) abrasive particles. Examples of useful abrasive particles include fused aluminum oxide-based materials such as aluminum oxide, ceramic aluminum oxide (which can include one or more metal oxide modifiers and/or seeding or nucleating agents), and heat-treated aluminum oxide, silicon carbide, co-fused alumina-zirconia, diamond, ceria, titanium diboride, cubic boron nitride, boron carbide, garnet, flint, emery, sol-gel derived abrasive particles, and mixtures thereof. The conventional abrasive particles can, for example, have an average diameter ranging from about <NUM> to about <NUM>, about <NUM> to about <NUM>, about <NUM> to about <NUM>, less than, equal to, or greater than about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. For example, the conventional abrasive particles can have an abrasives industry-specified nominal grade. Such abrasives industry-accepted grading standards include those known as the American National Standards Institute, Inc. (ANSI) standards, Federation of European Producers of Abrasive Products (FEPA) standards, and Japanese Industrial Standard (HS) standards. Exemplary ANSI grade designations (e.g., specified nominal grades) include: ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), ANSI <NUM> (<NUM>), and ANSI <NUM> (<NUM>). Exemplary FEPA grade designations include P12 (<NUM>), P16 (<NUM>), P20 (<NUM>), P24 (<NUM>), P30 (<NUM>), P36 (<NUM>), P40 (<NUM>), P50 (<NUM>), P60 (<NUM>), P80 (<NUM>), P100 (<NUM>), P120 (<NUM>), P120 (<NUM>), P150 (<NUM>), P180 (<NUM>), P220 (<NUM>), P240 (<NUM>), P280 (<NUM>), P320 (<NUM>), P360 (<NUM>), P400 (<NUM>), P500 (<NUM>), P600 (<NUM>), and P800 (<NUM>). An approximate average particles size of reach grade is listed in parenthesis following each grade designation.

Shaped abrasive particles or crushed abrasive particles can include any suitable material or mixture of materials. For example, shaped abrasive particles can include a material chosen from an alpha-alumina, a fused aluminum oxide, a heat-treated aluminum oxide, a ceramic aluminum oxide, a sintered aluminum oxide, a silicon carbide, a titanium diboride, a boron carbide, a tungsten carbide, a titanium carbide, a diamond, a cubic boron nitride, a garnet, a fused alumina-zirconia, a sol-gel derived abrasive particle, a cerium oxide, a zirconium oxide, a titanium oxide, and combinations thereof. In some embodiments, shaped abrasive particles and crushed abrasive particles can include the same materials. In further embodiments, shaped abrasive particles and crushed abrasive particles can include different materials.

Filler particles can also be included in abrasive. Examples of useful fillers include metal carbonates (such as calcium carbonate, calcium magnesium carbonate, sodium carbonate, magnesium carbonate), silica (such as quartz, glass beads, glass bubbles and glass fibers), silicates (such as talc, clays, montmorillonite, feldspar, mica, calcium silicate, calcium metasilicate, sodium aluminosilicate, sodium silicate), metal sulfates (such as calcium sulfate, barium sulfate, sodium sulfate, aluminum sodium sulfate, aluminum sulfate), gypsum, vermiculite, sugar, wood flour, a hydrated aluminum compound, carbon black, metal oxides (such as calcium oxide, aluminum oxide, tin oxide, titanium dioxide), metal sulfites (such as calcium sulfite), thermoplastic particles (such as polycarbonate, polyetherimide, polyester, polyethylene, poly(vinylchloride), polysulfone, polystyrene, acrylonitrile-butadiene-styrene block copolymer, polypropylene, acetal polymers, polyurethanes, nylon particles), thermosetting particles (such as phenolic bubbles, phenolic beads, polyurethane foam particles and the like) and natural gum (such as Arabic gum, Acacia gum, etc.). The filler may also be a salt such as a halide salt. Examples of halide salts include sodium chloride, potassium cryolite, sodium cryolite, ammonium cryolite, potassium tetrafluoroborate, sodium tetrafluoroborate, silicon fluorides, potassium chloride, magnesium chloride. Examples of metal fillers include, tin, lead, bismuth, cobalt, antimony, cadmium, iron and titanium. Other miscellaneous fillers include sulfur, organic sulfur compounds, graphite, lithium stearate and metallic sulfides. In some embodiments, individual shaped abrasive particles or individual crushed abrasive particles can be at least partially coated with an amorphous, ceramic, or organic coating. Examples of suitable components of the coatings include, a silane, glass, iron oxide, aluminum oxide, or combinations thereof. Coatings such as these can aid in processability and bonding of the particles to a resin of a binder.

At least one magnetic material may be included within or coated to abrasive particles. Examples of magnetic materials include iron; cobalt; nickel; various alloys of nickel and iron marketed as Permalloy in various grades; various alloys of iron, nickel and cobalt marketed as Fernico, Kovar, FerNiCo I, or FerNiCo II; various alloys of iron, aluminum, nickel, cobalt, and sometimes also copper and/or titanium marketed as Alnico in various grades; alloys of iron, silicon, and aluminum (about <NUM>:<NUM>:<NUM> by weight) marketed as Sendust alloy; Heusler alloys (e.g., Cu<NUM>MnSn); manganese bismuthide (also known as Bismanol); rare earth magnetizable materials such as gadolinium, dysprosium, holmium, europium oxide, alloys of neodymium, iron and boron (e.g., Nd<NUM>Fe<NUM>B), and alloys of samarium and cobalt (e.g., SmCo<NUM>); MnSb; MnOFe<NUM>O<NUM>; Y<NUM>Fe<NUM>O<NUM>; CrO<NUM>; MnAs; ferrites such as ferrite, magnetite; zinc ferrite; nickel ferrite; cobalt ferrite, magnesium ferrite, barium ferrite, and strontium ferrite; yttrium iron garnet; and combinations of the foregoing. In some embodiments, the magnetizable material is an alloy containing <NUM> to <NUM> weight percent aluminum, <NUM> to <NUM> wt% nickel, <NUM> to <NUM> wt% cobalt, up to <NUM> wt% copper, up to <NUM> % titanium, wherein the balance of material to add up to <NUM> wt% is iron. In some other embodiments, a magnetizable coating can be deposited on an abrasive particle <NUM> using a vapor deposition technique such as, for example, physical vapor deposition (PVD) including magnetron sputtering. Including these magnetizable materials can allow shaped abrasive particles to be responsive a magnetic field. Any of shaped abrasive particles can include the same material or include different materials.

Applied magnetic fields used in practice of the present disclosure have a field strength in the region of the magnetizable particles being affected (e.g., attracted and/or oriented) of at least about <NUM> gauss (<NUM> mT), at least about <NUM> gauss (<NUM> mT), or at least about <NUM> gauss (<NUM> T), although this is not a requirement. The applied magnetic field can be provided by one or more permanent magnets and/or electromagnet(s), or a combination of magnets and ferromagnetic members, for example. Suitable permanent magnets include rare-earth magnets comprising magnetizable materials are described hereinabove. The applied magnetic field can be static or variable (e.g., oscillating). Upper or lower magnetic members may be used, each having north (N) and south (S) poles, where each magnetic member be monolithic or may be composed of multiple component magnets and/or magnetizable bodies, for example. If comprised of multiple magnets, the multiple magnets in a given magnetic member can be contiguous and/or co-aligned (e.g., at least substantially parallel) with respect to their magnetic field lines where the components magnets closest approach each other. Stainless steel retainers may be used to retain the magnets in position. While stainless steel or an equivalent is suitable due to its nonmagnetic character, magnetizable materials may also be used. Mild steel mounts may be used to support stainless steel retainers.

Once the magnetizable abrasive particles are dispensed onto the curable binder precursor, the binder may be cured at least partially at a first curing station (not shown), so as to firmly retain the magnetizable particles in position. In some embodiments, additional magnetizable and/or non-magnetizable particles (e.g., filler abrasive particle and/or grinding aid particles) can be applied to the make layer precursor prior to curing. In the case of a coated abrasive article, the curable binder precursor comprises a make layer precursor, and the magnetizable particles comprise magnetizable abrasive particles. A size layer precursor may be applied over the at least partially cured make layer precursor and the magnetizable abrasive particles, although this is not a requirement. If present, the size layer precursor is then at least partially cured at a second curing station, optionally with further curing of the at least partially cured make layer precursor. In some embodiments, a supersize layer is disposed on the at least partially cured size layer precursor.

The shaped abrasive particles described herein may have a specified z-direction rotational orientation about a z-axis passing through shaped abrasive particles, where the z-axis of the abrasive may be substantially perpendicular to the wheel substrate. Shaped abrasive particles are orientated with a surface feature, such as a substantially planar surface particle, rotated into a specified angular position about the z-axis. The specified z-direction rotational orientation abrasive wheel occurs more frequently than would occur by a random z-directional rotational orientation of the surface feature due to electrostatic coating or drop coating of the shaped abrasive particles when forming the abrasive wheel. As such, by controlling the z-direction rotational orientation of a significantly large number of shaped abrasive particles, the cut rate, finish, or both of coated abrasive wheel can be varied from those manufactured using an electrostatic coating method. In various embodiments, at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> percent of shaped abrasive particles can have a specified z-direction rotational orientation which does not occur randomly and which can be substantially the same for all of the aligned particles. In other embodiments, about <NUM> percent of shaped abrasive particles can be aligned in a first direction and about <NUM> percent of shaped abrasive particles can be aligned in a second direction. In one embodiment, the first direction is substantially orthogonal to the second direction.

The specific z-direction rotational orientation of formed abrasive particles can be achieved through use of a precision apertured screen that positions shaped abrasive particles into a specific z-direction rotational orientation such that shaped abrasive particles can only fit into the precision apertured screen in a few specific orientations such as less than or equal to <NUM>, <NUM>, <NUM>, or <NUM> orientations. For example, a rectangular opening just slightly bigger than the cross section of shaped abrasive particles comprising a rectangular plate will orient shaped abrasive particles in one of two possible <NUM> degree opposed z-direction rotational orientations. The precision apertured screen can be designed such that shaped abrasive particles, while positioned in the screen's apertures, can rotate about their z-axis (normal to the screen's surface when the formed abrasive particles are positioned in the aperture) less than or equal to about <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> angular degrees.

The precision apertured screen, having a plurality of apertures selected to z-directionally orient shaped abrasive particles into a pattern, may include an abrasive retainer. The abrasive retainer may include an adhesive tape on a second precision apertured screen with a matching aperture pattern, an electrostatic field used to hold the particles in the first precision screen, a mechanical lock such as two precision apertured screens with matching aperture patterns twisted in opposite directions to pinch particles within the apertures, or other retentive mechanism. The first precision aperture screen may be filled with shaped abrasive particles, and the retaining member is used to hold shaped abrasive particles in place in the apertures. In one embodiment, adhesive tape on the surface of a second precision aperture screen aligned in a stack with the first precision aperture screen causes shaped abrasive particles to be retained in the apertures of the first precision screen stuck to the surface of the tape exposed in the second precision aperture screen's apertures.

Following positioning in apertures, a coated backing having make layer may be positioned parallel to the first precision aperture screen surface containing the shaped abrasive particles with make layer facing shaped abrasive particles in the apertures. Thereafter, coated backing and the first precision aperture screen are brought into contact to adhere shaped abrasive particles to the make layer. The retaining member is released such as removing the second precision aperture screen with taped surface, untwisting the two precision aperture screens, or eliminating the electrostatic field. Then the first precision aperture screen is then removed leaving the shaped abrasive particles having a specified z-directional rotational orientation on the coated abrasive article for further conventional processing such as applying a size coat and curing the make and size coats.

Additive manufacturing processes such as those described with respect to <FIG> allow creation parts which are not possible to produce using conventional methods. However, creating the part layer per layer presents a challenge because of the time needed to build each layer, reducing the range of potential products because the process cost.

One way to address that time constrain is to use a continuous process, where some or all of the 3D printing steps are done together at the same time. This can reduce the layer building time by more than half and increase the throughput of the printer.

The time needed for each different step is highly dependent of the powder or the mixture which is printed. A highly flowable powder can be spread and levelled much faster than a mixture having a poor flowability behavior. A highly conductive powder can be heated and dried faster than a refractory or ceramic material. Printing time is driven by the powder used but also by the precision needed on the final piece (driving the thickness layer) and by the needed strength to handle the printed part before the final consolidation step.

In the embodiments discussed above, no digitalization is included in any of the area and therefore no specific shape or feature can be introduced into the grinding wheel. In the embodiment of <FIG> and <FIG>, one or more binder jeet printheads are added, which allow for the printing of different shapes and wheels at the same time. It can also allow for printing different features on each printed grinding wheel. Such an embodiment combines the advantages of the digitalization of the traditional binder jet printer with the spiral continuous building process.

Designing a continuous process in which each operation can be done together during the same time, the process time can be divided at minimum by two. In the systems described below with respect to <FIG>, the basic principle of a spiral layer is kept but a binder jet printhead is added to allow for printing a lot of different abrasive articles in the same time or print different features on each printed grinding wheel.

<FIG> describe a continuous printing system that prints abrasive article precursors. It is expressly understood that the term "abrasive article" as used with respect to a product generated by a continuous printer can refer to both an abrasive article precursor that may require additional firing, such as vitreous or metal bonded abrasive particles, as well as abrasive articles that are substantially finished products without additional firing requirements, such as resin bonded abrasive articles.

<FIG> and <FIG> illustrate a platform for continuous additive manufacturing of an abrasive product. Platform <NUM> allows for faster continuous manufacture of abrasive products by allowing several steps in the process to be completed simultaneously. The basic steps for additive manufacturing of an abrasive product using a binder jet system include spreading the abrasive mixture, leveling the layer, printing binder, and setting the layer.

In one embodiment, platform <NUM> has a disc-shape <NUM>. The shape of disc <NUM> is sized to being able to print multiples abrasive articles in a specific size range. For example, the individual abrasive articles may have sizes ranging from about <NUM> diameter up to about <NUM> diameter after sintering are selected.

In one example, disk <NUM> has about a <NUM> outer diameter, about a <NUM> inner diameter, about a medium length of <NUM>, with approximately <NUM><NUM> platform surface. This represents a significant increase in available surface area compared to prior art additive manufacturing processes.

Disc <NUM> can move in space as indicated by arrows <NUM> and <NUM>. In one embodiment, a motor allows for disc <NUM> to move up and down as indicated by arrow <NUM>. Another motor, in one embodiment, allows for disc <NUM> to move rotationally as indicated by arrow <NUM>. Motors allowing for movement in directions <NUM> and <NUM> may be step motors or any other suitable movement mechanism.

In one embodiment (not show in <FIG> and <FIG>), platform <NUM> is surrounded by a cylinder that keeps abrasive mixture from spilling outside of the platform area. Use of a cylinder may allow for recapture of abrasive mixture that is not incorporated into an abrasive product. For example, using a temporary binder, it is possible to print an abrasive article with complex internal structure, such as the shapes and structures discussed in co-owned provisional patent application Serial No. <CIT>, and <CIT>. For example, a bonded abrasive article can be constructed using binder jet methods described herein, to have arcuate, tortuous, or straight channels extending partway or completely throughout. Bonded abrasive articles can also be constructed with structures extending only partway through, and can include impeller structures that direct cooling fluids to the grinding area. Additionally, channels may extend from an interior to an exterior surface of the bonded abrasive article.

A hopper <NUM> is present on disc. Hopper <NUM> contains the abrasive mixture to be printed. In an embodiment where the abrasive article is a vitreous bonded abrasive article, the abrasive mixture to be printed includes abrasive particles as well as binder precursor particles. The abrasive mixture may be premixed, in one embodiment. In another embodiment, hopper may include a mixing component. For a vitreous bonded abrasive article, the binder precursor could include vitreous frit, glass, or other suitable materials. In an embodiment where the abrasive article is a metal bonded or polymer bonded article, the binder precursor could include metal powder or polymer powder, respectfully. The abrasive mixture may also include, in other embodiments, other material such as filler, secondary abrasives, grinding aids or other suitable additives. Methods and systems described herein may also be suitable for resin based abrasive articles. In such embodiments, the resin binder could be dispensed as part of the abrasive mixture. A temporary binder may still be used to encourage aqueous, phenolic based or other solvent-based bonding. A temporary binder may also be dispensed as part of the abrasive material, which may react with a compound dispensed by a dispenser, such as dispenser <NUM>.

Hopper <NUM> is illustrated as an open component that can, in some embodiments, be filled from an external source (not shown). Filling periodically, or continuously, from an external source may allow for a smaller hopper <NUM>, relative to platform <NUM>, allowing more space on disc <NUM> for additional components. A smaller hopper <NUM> also reduces the total vertical footprint of platform <NUM>.

Hopper <NUM> also facilitates dispensing of the abrasive mixture onto a platform. Hopper may dispense the abrasive mixture or provide it to a dispenser for placement. Dispensing of the abrasive mixture can occur in any suitable matter, such as vibrating hopper <NUM>, vibrating sieve, opening a dispensing panel, using an electromagnetic feeder or through any other suitable mechanism. In one embodiment, a sieve is placed below hopper <NUM> to facilitate even distribution of the abrasive mixture.

A leveling tool <NUM> is present to distribute the dispensed abrasive mixture evenly along a width <NUM> of disc <NUM>. In some embodiments leveling blade <NUM> has an angle with respect to disc <NUM> to facilitate movement of powder across width <NUM>. In some embodiments, a second levelling tool (not shown) is placed near leveling tool <NUM>. In one embodiment, the second leveling blade is closer to the platform than the first one and has a different angle.

In some embodiments, a rotating leveler <NUM> is also present behind leveling tool <NUM>. Rotating leveler <NUM>, in some embodiments, is closer to disc <NUM> than levelling tool <NUM>. Rotating leveler <NUM> increases density of the deposited abrasive material. Density of the deposited abrasive material can directly affect the abrasive performance of a final abrasive article. Depending on the final product, different densities are desired. For example, a less dense, and more porous, bonded abrasive may be useful for abrading operations where large chips are created and need to be removed such as during creep feed grinding or where lubricant is used as the pores can help bring and maintain lubricant at an active grinding area, preventing burning of the workpiece being abraded. More dense bonded abrasive products may be useful when a higher lifetime is requested.

Densification, or compaction, of deposited abrasive material can be accomplished, as illustrated in <FIG>, by combining a leveling tool <NUM> and a leveler <NUM> at different distances from disc <NUM>. The different distances of leveler <NUM> and <NUM> can be adjusted based on the abrasive grit size or precision requested for the final abrasive article. Densification can be further accomplished, for example, using vibration, local compaction or any other suitable method.

In some embodiments, the height of different components can be adjusted during the printing process to increase the printing speed when parts or section can accept a thicker layer. Adjusting the height of different components can increase building speed by keeping the fine details of each component where it is needed.

A binder jet printhead <NUM> is located behind leveler <NUM>. Binder jet printhead <NUM> dispenses a binder material on the deposited abrasive mixture in a desired pattern. The binder jet printhead <NUM> may have several nozzles (not shown in <FIG>), each of which can dispense binder material.

In embodiments where the abrasive mixture includes a binder precursor that will be activated during a later process, binder jet printhead <NUM> dispenses a temporary binder. In the example of a metal bond or vitreous bond abrasive article, the temporary binder is selected such that it will be burnt out during a later sintering process. In the example of a resin bond abrasive article, for some embodiments, the temporary binder is removed before curing of a high temperature resin, or combined with the resin in the curing process.

Additionally, in some embodiments the temporary binder may remain present in the final abrasive article. The temporary binder may also be included, in some embodiments, in the abrasive mixture and may react with a dispensed liquid material to form a binder. This may reduce the amount of binder that is dispensed through the nozzles.

As illustrated in <FIG>, binder print jet <NUM>, in one embodiment, is mobile, such that it can move along the axis indicated by arrow <NUM>, such that an entire width <NUM> can receive binder material in a desired pattern. Movement of printhead <NUM> can be driven by a step motor having an encoder to know where the nozzles lines are positioned in front of the platform.

In some embodiments, the binder material is deposited by printhead <NUM> as a diluted aqueous mixture, solvent based mixture or phenolic based mixture. Binder material is often a naturally viscous material that is not easily dispensed through binder jet nozzle arrays. Dilution reduces a viscosity of the binder to a point where it can be dispensed easily through the nozzles.

The binder material is deposited by an array of nozzles present on printhead <NUM>. In one embodiment, the array of nozzles is a square array of nozzles. The array may have at least about <NUM> nozzles, in one embodiment, or at least about <NUM> nozzles, or at least about <NUM> nozzles, or at least about <NUM> nozzles. Dispensing of binder material by the nozzles on printhead <NUM> is controlled by a controller (not shown in <FIG>), which determines the number and rate of droplets released from each nozzle based on the intended abrasive articles being printed. For example, the rate of binder dispensation may depend at least in part on: pieces to print, mixture particles sizes, mixture particle material, green strength needed, number of nozzles per printhead <NUM>, nozzle size, droplet frequency, droplet rate, printhead linear speed, layer thickness or other relevant parameters.

In some embodiments, printhead(s) <NUM> will be able to move regularly in front of a cleaning station and a parking station (neither shown in <FIG>). Parking and cleaning stations may be placed closer to the center of platform <NUM> or close to the external diameter of platform <NUM>, as illustrated for example in <FIG>, discussed below.

Also present within platform <NUM> is a setting station <NUM> which facilitates setting of each layer of deposited abrasive material in between layers. The amount of setting needed for each layer of deposited powder is a function of the amount of abrasive material deposited, the heat produced by setting station <NUM>, and the speed of rotation of disc <NUM>. Setting may be accomplished by applying a vacuum to remove excess fluid, subjecting the layer to a blower, by thermally drying the layer, thermally curing the layer, UV-curing the layer, or otherwise treating the layer. Setting may also be dictated, at least in part, based on parameters needed for later processing. For example, vitreous abrasive articles made using additive manufacturing require a final sintering step at a high temperature. Additionally, at least some resin-bonded abrasive articles require a final sintering step.

While setting station <NUM> is illustrated, it is expressly contemplated that, for some abrasive articles, setting may not be needed for each layer. For example, some abrasive articles may only undergo a drying step after all layers, or a subset of layers, are printed. In some embodiments, such as where a reactive temporary binder is included in the abrasive mixture, intermittent drying of each layer is not needed for structural integrity.

A motor will move platform <NUM> down during the additive manufacturing process to progressively increase the total layers in the spiral. The speed of the motor can be adjusted based on the define thickness layer and the rotation speed. The motor may operate continuously or discretely.

The finished abrasive article can be removed when the additive manufacturing process is completed, for example by adjusting disc <NUM> along axis <NUM>.

Rotational movement of platform <NUM> can also be controlled by a step motor. Speed of rotation is driven by a number of factors including flowability of the abrasive mixture, binder dispensation and saturation rate, setting time available, and leveling of each layer. The flowability of the abrasive mixture influences the spreading of the powder and, thus, the levelling of each layer without disturbing the previous layer.

Not shown in <FIG> is a controller that will drive the operation of different components, positioning of disc <NUM> and the relative position of each of components <NUM>, <NUM>, <NUM>, <NUM> and <NUM> with respect to disc <NUM>. Movement and dispensation rate of printhead <NUM> will also be dictated by instructions sent from the controller. Movement of step motors and encoders will also be dictated by instructions sent from the controller. Additionally, the controller will also facilitate safety functions to protect both an operator and a machine, including guards, maximum and minimum movement speeds and end switches.

The controller may also, in one embodiment, retrieve and interpret 3D files for the abrasive articles to be printed, such as CAD or STL files. The controller may also interpret the 3D files to determine placement of abrasive articles to be printed on platform <NUM>.

Rotational movement of disc <NUM> is at a continuous rate in direction <NUM>, in one embodiment. In another embodiment, rotational movement is discrete, such that disc <NUM> walks through several discrete positions, during which different operations are performed. The printed abrasive articles are formed in a spiral on disc <NUM>, which is continuously moved downward to allow for increasing height of the abrasive articles being formed. In one embodiment, printhead <NUM> is continuously jetting droplets on the powder bed to generate abrasive articles.

While single hopper <NUM> is illustrated as containing a single homogenous mixture, it is expressly contemplated that, in some embodiments, hopper <NUM> includes several compartments. Each compartment may contain different abrasive mixtures. For example, the portion of an abrasive article near the core may not need to contain high grade abrasive mineral, which is expensive. Instead, one or more interior compartments close to a core may contain an abrasive mixture with lower cost materials.

Use of systems described herein in <FIG>, therefore, allow for bonded abrasive articles with abrasive mixtures that can vary from layer to layer, or even between a first and second area in a layer.

<FIG> illustrates another embodiment in which multiple components are mirrored in the free space of disc <NUM>. This may allow for two layers of abrasive material to be deposited for each rotation of disc <NUM>, increasing therefore the object building speed. Similar components are numbered similarly with respect to 7A. For example, hopper 720a dispenses a first layer of abrasive mixture, which is then leveled by leveling tool 730a, and compacted by leveler 740a, receives binder from binder jet printhead 750a and is then dried by setting station 760a. After the first layer is dried by setting station 760a, the process repeats with the 'b' components. This allows a single working area 790a to receive two layers of abrasive material and binder each time disc <NUM> completes a rotation.

Use of two different sets of components allows for different layer structures to be formed - for example a first layer with a first abrasive mixture, dispensed from hopper 720a followed by a second layer with a second abrasive mixture, dispensed from hopper 720b. This may allow for unique structures with different properties in different layers. For example, a first layer may have a different porosity, hardness, density, abrasive particle composition, abrasive particle size, or abrasive particle orientation than a second layer.

The presence of additional sets of components, e.g. set 'a' and set 'b' depends in the amount of available space left on disc <NUM> after sufficient setting occurs. For abrasive articles where minimal setting is needed, or where a setting component is at a sufficient temperature, more than two sets of components may be present, such that three or even four layers can be deposited per rotation.

<FIG> illustrate a platform for continuous additive manufacturing of an abrasive product. <FIG> illustrates a top view of a similar set of components as those described with respect to <FIG>, and similar components are labeled similarly. <FIG> illustrates a side view of the continuous additive manufacturing system <NUM>. However, instead of a moving printhead, as described with respect to printheads 750a and 750b, <FIG> illustrates an embodiment with stationary arrays of printheads 850a, 850b. Keeping printhead arrays 850a and 850b stationary reduces the complexity required to program dispensing of the binder material as a controller (not shown in <FIG>) is not required to program movement of printhead arrays 850a and 850b as well as dispensation of binder therefrom. In the embodiment illustrated in <FIG>, each printhead array 850a, 850b includes six printheads. In one embodiment, each printhead includes at least about <NUM> nozzles, each allowing for jetting up to <NUM>, <NUM> or even 160pl of binder fluid at <NUM>. Additionally, while only six printheads are shown there could be more than six, such as eight, nine, ten, twelve or more, in an array, or fewer than six, such as two, three, four or five. The number may be selected balancing the precision needed and increasing the assembly speed.

<FIG> illustrates a side view of a platform for continuous additive manufacturing, illustrating the variable distance between the components and the platform.

<FIG> illustrates an example platform with a cleaning station <NUM> and a parking station <NUM>.

<FIG> and <FIG> illustrate example arrangements of printed abrasive articles. Preferably, a combination of abrasive articles are manufactured within a workspace on a platform, such as platform <NUM>, <NUM> or <NUM>. As illustrated in <FIG> and <FIG>, different arrangements of different abrasive articles can be assembled on a given workspace <NUM>, <NUM> during a single additive manufacturing operation. Different shapes and sizes of abrasive articles can be manufactured on a different workspace, so long as all are formed from the same abrasive mixture.

The workspace available for additive manufacturing corresponds to a width of the rotating platform, width <NUM> for example. Length <NUM> of workspace <NUM> corresponds to width <NUM>, for example. A width <NUM> of workspace <NUM> can vary depending on the embodiment. In some embodiments, different workspaces <NUM> can be arranged to cover substantially all of the available area on a platform.

<FIG> illustrates a block diagram of a continuous printer. Continuous printer <NUM> includes a surface <NUM> with one or more workspaces <NUM>. Each workspace is designed to serve as a base on which abrasive articles can be additively manufactured.

Surface <NUM> is configured to be rotated, while other components are intended to function in a substantially fixed arrangement. During one rotation of surface <NUM>, each workspace <NUM> receives at least one layer of abrasive material and binder. However, in some embodiments, during one rotation of surface <NUM>, each workspace <NUM> receives at least two layers of abrasive material and binder, or at least three layers, or at least four.

Continuous printer includes a materials source <NUM>. A given printing operation may require more material than on-board dispensers of printer <NUM> can store. Additional abrasive material can be provided from abrasive material source <NUM>. Temporary binder material can be provided by a temporary binder material source <NUM>. Other material, such as filler, can be provided from an other material source <NUM>.

Abrasive material, provided by abrasive material source <NUM>, includes abrasive particles, which may be shaped, crushed or platey-type abrasive particles. In the embodiment where vitreous abrasive articles are being manufactured, abrasive material source also comprises vitreous bond precursor particles, such as glass frit. In the embodiment where metal bond abrasive articles are being manufactured, abrasive material source also comprises metal bond precursor particles, such as metal powder.

In the embodiments where further processes are required to activate bond precursor materials, a temporary binder material is dispensed in order to hold the abrasive article precursor together during the additive manufacturing process. The temporary binder material is selected such that it will burn out during later processing and not be present in the final article.

Functionality of continuous printer <NUM> is controlled by a controller <NUM>, which may be a processor or microprocessor. Controller <NUM>, for example, sets and controls a speed <NUM> of rotation of surface <NUM>. The rate may be set based on flowability of abrasive material, necessary setting time, binder dispensation rates, or any other suitable parameter.

Controller <NUM> controls dispensing of materials onto each of workspaces <NUM>. Abrasive material is dispensed by an abrasive material dispenser <NUM> at an abrasive material dispensing rate <NUM>. Abrasive material dispenser may be a hopper, and dispensing may include vibrating the hopper or otherwise causing abrasive material to fall from the hopper onto a workspace <NUM>.

After a layer of abrasive material is dispensed from abrasive material dispenser <NUM>, the abrasive material is leveled across workspace <NUM> by a leveler <NUM>. Leveler <NUM>, in one embodiment, evens out the abrasive material to a substantially even height across workspace <NUM>. In another embodiment, a leveling mechanism <NUM> also provides a compacting operation, causing densification of the abrasive material mixture. The leveler <NUM>, or levelers <NUM>, are at a variable height above workspace <NUM>. In the embodiment where two or more levelers <NUM> are present, the levelers <NUM> may be at different heights with respect to each other. Positioning <NUM> of the levelers with respect to a workspace is controlled by controller.

The abrasive material mixture is held in place during manufacturing by temporary binder material which is provided by temporary binder material dispenser <NUM>, which is located in a dispensing station <NUM> of printer <NUM>. Controller <NUM> controls the binder dispensing rate <NUM>, and distribution <NUM> of binder along the surface of the dispensed abrasive mixture. Temporary binder material dispenser, in one embodiment, is a jet printhead including an array of nozzles, each nozzle configured to output droplets of binder material onto a given area of workspace <NUM>. Controller <NUM> controls which nozzles output binder material, and at what rate <NUM>, in order to temporarily bind abrasive material mixture into a desired shape for each layer of an abrasive article being manufactured.

Controller <NUM> also controls settings for setting station <NUM>, including setting parameters <NUM>. Setting station <NUM> is designed such that the binder material dispensed in a current layer on workspace <NUM> is sufficiently dried after exposure to setting station <NUM> such that another layer of abrasive material mixture can be dispensed by abrasive material dispenser <NUM> without causing structural integrity problems.

Controller <NUM> also controls other specifications <NUM> of printer <NUM>, and triggers safety function <NUM> as needed in order to protect an operator or printer <NUM>.

Controller <NUM> may also cause temporary binder material dispenser <NUM> to interact with a cleaning station <NUM> either periodically, or in response to an alert from a sensor <NUM>. It is possible that abrasive material will become attached to a nozzle or other dispensing mechanism of temporary binder material dispenser. This can result in a clog, which reduces the precision of binder material dispensing in each layer. Periodically, or in response to a notice of a detected clog from a sensor <NUM>, controller <NUM> may direct temporary binder material dispenser <NUM>, or an affected portion thereof, to interact with a cleaning station. Cleaning station <NUM> may include a brush, a vibrating mechanism, or another device suitable for cleaning off a clogged dispenser.

Controller <NUM> directs operation of the components of continuous printer <NUM> based on the shapes of abrasive articles being manufactured. Shape information is retrieved from database <NUM>, which may store shape files <NUM>, such as CAD or STL files. A distribution of shapes <NUM> for a workspace may also be stored in database <NUM>. Alternatively, controller <NUM> may determine a distribution of shapes <NUM> based on retrieved shape files <NUM> for a given operation. Controller also retrieves printer parameters <NUM>, such as setting parameters, movement rates, dispensing rates of different material dispensers, and other relevant parameters.

Controller <NUM> also controls movement mechanisms <NUM> and <NUM>. Movement mechanisms may be any suitable motor, such as a step motor, operating discretely or continuously. Rotation mechanism <NUM> causes rotational movement of surface <NUM>, such that each workspace <NUM> interacts with each of dispensers <NUM>, <NUM>, leveler <NUM>, and setting station <NUM> at least once during a rotation. However, while only one of each component is described with respect to <FIG> for simplicity, it is expressly contemplated that, for example, a workspace <NUM> may receive two or more layers of abrasive material and temporary binder during a rotation.

Controller <NUM> also controls a variety of sensors <NUM> that may be present within continuous printer <NUM>. Sensors <NUM> may be optical, cameras, or thermometers, for example. Sensors can be used to measure quality control of abrasive articles during assembly, including monitoring curing of temporary binder, measuring hardness, porosity and / or density of abrasive article as well as other mechanical properties. Sensors <NUM> are envisioned as including any in-line measurement that can help with quality control. Sensors <NUM> may also monitor fill levels for abrasive material dispenser <NUM>, temporary binder material dispenser <NUM>, and other material dispenser <NUM>, such that additional material can be provided by a material source <NUM> as needed.

<FIG> illustrates a method of manufacturing an abrasive article using a continuous printer. Method <NUM> may be suitable with any of the continuous printers of <FIG>, or another suitable continuous printer.

In block <NUM>, an abrasive mixture is dispensed on a workspace. The workspace, in one embodiment, is a moving workspace. The abrasive mixture may be dispensed on a continuously moving workspace, in one embodiment. In another embodiment the workspace moves discretely between positions, one of which is to receive the abrasive mixture.

The abrasive mixture, in one embodiment, includes abrasive particles, such as shaped, crushed or platey abrasive particles. The abrasive mixture may also include binder precursor particles, in embodiments where a final abrasive article is a vitreous, polymeric, resin or metal-based bond. The abrasive mixture may also include filler material or material that delivers a desired mechanical property to the final abrasive article including porosity, density, or hardness.

In block <NUM>, the abrasive mixture is leveled. Leveling includes spreading out the abrasive mixture to a substantially consistent height across a workspace.

In block <NUM>, the abrasive mixture is compacted. Compacting can be an important step to increase the density of the final abrasive article. In some embodiments, leveling also includes compacting the abrasive mixture, such that steps <NUM> and <NUM> are performed by similar tools, or even performed simultaneously. For example, increasing the bulk green density by <NUM>% on a vitreous bonded abrasive mixture can save <NUM>% porosity after sintering and increase hardness by several degrees. Pre-compacting causes less density decrease than when un-compacted. For example, for completely pressed wheels there may be negligible decrease in density. For additively manufactured abrasive wheels, the decrease may be higher, and compaction may move the density change in between additively manufactured wheels without compaction and closer to pressed wheels.

In block <NUM>, binder material is dispensed. The binder material is dispensed as a liquid from one or more liquid dispensing sources. For example, the binder material may be dispensed by a moving printhead of a binder jet printer, where the binder jet printhead moves across the workspace depositing binder material to create a desired design for the layer of the abrasive article that includes the dispensed abrasive mixture. In another embodiment, the binder material is dispensed by a static dispensing source, such as an array of binder jet printheads, or an array of nozzles. In some embodiments, the binder material is a temporary binder material configured to be removed, or often burnt out, during later setting and firing processes. The binder material may be a dilute binder material, for example in an aqueous, solvent based, phenolic based or other suitable solution.

In block <NUM>, the dispensed binder material undergoes a setting step. The setting step may include heating a workspace, and the layered material on the workspace, to a temperature that allows for curing or setting of the dispensed temporary binder material. Setting may also include thermally drying the dispensed abrasive material and binder on the workspace. Setting may also include UV-curing or other suitable curing mechanism. Setting is an important step to ensure structural integrity of the abrasive article being assembled during deposition of future layers. The method of setting may be selected based on the treatment needed to fix the temporary binder or the amount of binder applied. In the event a dilute binder is used, the water or other solvent may need to be removed, which may also be part of the setting process.

At decision point <NUM>, the abrasive article is either complete, in which case method <NUM> proceeds to block <NUM>. If the abrasive article is not yet complete, method <NUM> returns to block <NUM>, where another layer of abrasive mixture is deposited. In some embodiments, such as those illustrated in <FIG>, method <NUM> creates a spiral of abrasive material layers as the abrasive article is built.

In block <NUM>, a finished abrasive article is removed from the continuous printer. Removal may include moving the abrasive article off of a workspace and subjecting it to further processing. For example, a vitreous or metal-bonded abrasive article usually undergoes an additional firing process to facilitate melting or sintering of the bond precursor particles and burnout of the temporary binder. Polymer-bonded abrasive articles may also undergo another processing step to facilitate polymerization. Depending on the final product required by the customer, the abrasive product can be glued on a shaft or on a support, can be machined to specific required size, balance, and being marked.

Various embodiments of the present disclosure can be better understood by reference to the following Examples which are offered by way of illustration. The present invention is defined by the claims and is not limited to the Examples given herein.

In the configuration illustrated in <FIG>, the platform surface has <NUM><NUM>. Using material from <NUM> Precision Grinding GmbH, St. Magdalener Straße <NUM>, <NUM> Villach - Austria, specifically 8A120J6V601 or 95DA120/220H7V301, as examples, with an intended layer thickness of <NUM>, a saturation of <NUM>%, a PR of <NUM>%. The nozzle covering surface is <NUM><NUM> with a droplet volume of 160pL, assuming <NUM>% of nozzles are efficient, which is an estimate considering defects after long usage. The printing speed was simulated as <NUM>/s at the average diameter, which was limited by the levelling roller station as the printhead speed could reach several meters per minute otherwise. Calculation shows that <NUM> rows of nozzles are needed to drop the required amount of binder. If a thicker layer is needed with the same saturation, an additional pair of rows must be added. The time needed to print a <NUM> layer was simulated at <NUM> for the mirrored design which means <NUM><NUM>/s.

This can be compared to <NUM> achieved by M-Flex® printer (available from ExOne with corporate headquarters in North Huntingdon, PA) with similar material and similar parameters, which equates to <NUM><NUM>/s. This simulation shows that embodiments of the present invention can achieve throughput of up to <NUM>-<NUM> times higher for the mirrored design of <FIG> and <FIG>, and <NUM>-<NUM> times the throughput for the design of <FIG>. This value includes the pause printing time needed to clean printhead at the cleaning station.

Claim 1:
An abrasive wheel maker apparatus (<NUM>) for forming a continuous single layer bonded abrasive wheel, comprising:
a wheel substrate (<NUM>) having a dispensing surface;
an abrasive material dispenser (<NUM>) configured to dispose a binder precursor onto a circular section of the dispensing surface and to dispose a plurality of abrasive particles at least partially within the binder precursor; and
a rotation device configured to rotate the dispensing surface relative to the abrasive material dispenser;
the apparatus being characterized in that if further comprises: a leveler (<NUM>) configured to level the layer of the abrasive mixture at a leveling location, such that the layer has a substantially smooth surface;
a compacting tool (<NUM>) configured to compact the layer of the abrasive mixture at a compacting location, such that a density of the layer of abrasive mixture increases;
a liquid dispenser (<NUM>) configured to apply a liquid material from a liquid dispenser at a liquid dispensing station, to the compacted layer of abrasive mixture;
a setting station (<NUM>) configured to allow the layer of abrasive mixture and dispensed liquid to set.