Patent ID: 12186935

The drawing figures do not limit the invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

DETAILED DESCRIPTION

The subject matter of the invention is described in detail below to meet statutory requirements; however, the description itself is not intended to limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Minor variations from the description below will be understood by one skilled in the art and are intended to be captured within the scope of the claimed invention. Terms should not be interpreted as implying any particular ordering of various steps described unless the order of individual steps is explicitly described.

The following detailed description references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the technology can include a variety of combinations and/or integrations of the embodiments described herein.

Example of the System

FIG.1illustrates an example of a system for joining a first additively manufactured ceramic green body to a second additively manufactured ceramic green body for some embodiments. In some embodiments, system100comprises first ceramic green body102. In some embodiments, first ceramic green body102is additively manufactured. For example, first ceramic green body102may be manufactured using 3D-printers such as: selective laser sintering printers, fused deposition modeling printers, digital light process printers, stereolithography printers, multi-jet fusion printers, polyjet printers, direct metal laser sintering printers, electron beam emitting printers, or any other 3D printer method. In some embodiments, first ceramic green body102may be manufactured from a resin-ceramic slurry.

In some embodiments, the resin-ceramic slurry may comprise a mixture of resin and ceramic powder that is sintered to solidify the ceramic powder and remove the resin thereby shrinking the total volume of the resin-ceramic slurry. In some embodiments, the ratio of resin to ceramic determines the amount the resin-ceramic slurry shrinks during sintering. For example, a ratio of 1:1 (i.e., 50% resin and 50% ceramic powder) may shrink 50% during sintering. Additionally, for example, a ratio of 1:2 (i.e., 33.3% resin and 66.7% ceramic powder) may shrink 33.3% when sintered. In some embodiments, the resin-ceramic slurry may comprise materials other than resin and ceramic powder. For example, the resin-ceramic slurry may comprise a plastic and ceramic chunk slurry. In some embodiments, sintering the resin-ceramic slurry may increase the density of resulting part by removing the resin material from the part leaving only the ceramic powder.

In some embodiments, first ceramic green body102may comprise first joint surface104. In some embodiments, first joint surface104may comprise a joint configured to connect to a second joint surface. For example, first joint surface104may comprise an angled cut matching a second angled cut in second joint surface112. In some embodiments, first joint surface104is interfaced with second joint surface112such that first ceramic green body102and second ceramic green body110combine forming unitary part202(depicted inFIG.2). In some embodiments, first joint surface104may be manufactured from the same resin-ceramic slurry used to manufacture first ceramic green body102. In some embodiments, first joint surface104may comprise interfacing features such as dovetail joints, interlocking teeth, or any other such interfacing feature that provides a rigid connection. Further examples of interfacing features can be found described with second joint surface112below.

In some embodiments, first ceramic green body102may comprise first support structure106. In some embodiments, first support structure106may extend from first ceramic green body102. In some embodiments, first support structure106is separated from first ceramic green body102by applying a force along a predetermined area/surface of first support structure106. In some embodiments, the predetermined area/surface is a separable feature. In some embodiments, first ceramic green body102comprises first separable features130. In some embodiments, first support structure106is configured to break away from first ceramic green body102via first separable features130. In some embodiments, first separable features130may comprise a low percentage contact surface configured to provide contact between first support structure106and first ceramic green body102. For example, first separable features130may only contact 5-10%, 5-15%, 5-20%, or 5-25% of first ceramic green body102such that first support structure106may be separable from first ceramic green body102. First separable features130may comprise pyramidal features having a low percentage of contact between first support structure106and first ceramic green body102. In some embodiments, first separable features130may have a high area of contact on first support structure106and a low area of contact on first ceramic green body102.

In some embodiments, first support structure106may comprise first support joint surface108. In some embodiments, first support joint surface108may comprise joining features configured to interface with a second support joint surface having similar joining features (second ceramic green body110and second support structure114as described below). In some embodiments, first support joint surface108may comprise a ceramic material. In some embodiments, first support joint surface108is configured to shrink during a sintering process. In some embodiments, first support joint surface108may shrink in a first shrinking direction based upon the print direction of first support structure106.

In some embodiments, first support joint surface108may be configured to interface with a second support joint surface integrated into second joint surface112of a second ceramic green body. For example, first support joint surface108may comprise a sawtooth pattern matching a sawtooth pattern in a second support joint surface. First support joint surface108and the second support joint structure may be interfaced and then sintered to combine first support joint surface108and the second support joint surface to form a unitary support structure.

In some embodiments, first ceramic green body102, first joint surface104, first support structure106, and first support joint surface108may be comprised of a resin-ceramic slurry that is sintered to solidify the resin-ceramic slurry. In some embodiments, the resin-ceramic slurry may be configured to shrink during sintering. For example, first ceramic green body102may be manufactured using a resin-ceramic slurry comprising 50% ceramic powder and 50% resin. During sintering, the resin may be melted or burned away resulting in a 50% reduction in size of first ceramic green body102post sintering. In some embodiments, the resin-ceramic slurry may comprise any ratio of ceramic to resin.

In some embodiments, system100comprises second ceramic green body110. In some embodiments, second ceramic green body110may be substantially similar to first ceramic green body102. In some embodiments, second ceramic green body110may be substantially different from first ceramic green body102while still sharing some features. In some embodiments, second ceramic green body110may have a print direction distinct from the print direction of first ceramic green body102. In some embodiments, second ceramic green body110may comprise a second joint surface.

In some embodiments, second ceramic green body110comprises second joint surface112that is configured to interface with first joint surface104. In some embodiments, second joint surface112comprises an angled cut substantially similar to the angled cut present in first joint surface104. In some embodiments, second joint surface112may be any type of joining element. For example, second joint surface112may comprise interfacing features such as interlocking tabs, dovetail joints, mortise and tenon joints, butt joints, lap joints, miter joints, scarf joints, dowel joints, rabbet joints, or any other such joining surface. In some embodiments, second joint surface112is configured to join with first joint surface104while being supported by second joint surface112.

In some embodiments, second ceramic green body110comprises second support structure114. In some embodiments, second support structure114is configured to provide support to second ceramic green body110during sintering. In some embodiments, second support structure114is configured to resist flexion of second ceramic green body110during sintering. In some embodiments, second support structure114may be oriented horizontally such that second support structure114prevents horizontally inward flexion during sintering. In some embodiments, second support structure114may extend between a first edge122aand second edge122bof second ceramic green body110thereby counteracting horizontal flexion between the first edge122aand the second edge122band preventing damage to second ceramic green body110. In some embodiments, second support structure114may extend between at least two edges of second ceramic green body110. In some embodiments, second support structure114is configured to interface with first support structure106.

In some embodiments, second support structure114may comprise second support joint surface116. In some embodiments, second support structure114is configured to interface with first support structure106by interfacing second support joint surface116and first support joint surface108. In some embodiments, second support joint surface116is interfaced with one or more support joint surfaces substantially similar to first support joint surface108. For example, second support joint surface116and first support joint surface108may comprise matching square protrusions. In some embodiments, second support structure114and second support joint surface116may be configured to separate from second ceramic green body110post sintering. In some embodiments, second support joint surface116is separated from second ceramic green body110by applying a force along a predetermined surface. In some embodiments, the predetermined surface is a separable feature such as first separable features130.

In some embodiments, second support structure114may comprise second separable features132substantially similar to first separable features130such that second support structure114may be separated from second ceramic green body110after sintering is completed. In some embodiments, second separable features132comprise pyramidal features configured to connect second support structure114and second ceramic green body110. In some embodiments, second separable features132may be configured to contact only a small surface of second ceramic green body110. For example, first separable features130may be configured to contact 5-10%, 5-15%, 5-20%, or 5-25% of second ceramic green body110. It is contemplated that second separable features132may be configured to contact any percentage of second ceramic green body110such that second support structure114may be separated from second ceramic green body110after sintering without departing from the scope of the present disclosure.

In some embodiments, first ceramic green body102may comprise additive manufacturing supports for providing structural support during additive manufacturing. For example, first ceramic green body102may require additively manufacturing an arch, bridge, or other floating structure. To support the floating structure, additive manufacturing supports may be constructed underneath the floating structure. In some embodiments, the additive manufacturing supports may comprise the same resin-ceramic slurry as first ceramic green body102. In some embodiments, the additive manufacturing supports may comprise a dissolvable material that can be submerged in water to decompose the additive manufacturing supports. In some embodiments, the additive manufacturing supports may comprise polyvinyl alcohol, polylactic acid, wax, sodium silicate, potassium silicate, ceramic powders or any other such material.

In some embodiments, first ceramic green body102and second ceramic green body110may comprise separate materials such that first ceramic green body102shrinks according to a first dimension and second ceramic green body110shrinks according to a second dimension. In some embodiments, first ceramic green body102and second ceramic green body110may be additively manufactured using a first print direction and a second print direction respectively. The first print direction and the second print direction may be entirely parallel and/or the same direction. The first print direction may be perpendicular to the second print direction. In some embodiments, the first print direction may be oriented at an angle according to the second print direction. In some embodiments, the first and second print direction may be non-parallel at an arbitrary angle. In some embodiments, the first print direction and the second print direction may determine the direction first ceramic green body102and second ceramic green body110shrink respectively. In some embodiments, first ceramic green body102may shrink according to a first dimension and second ceramic green body110may shrink according to a second dimension. For example, first ceramic green body102may have a print direction wherein each layer includes a longitudinal cross-section of first ceramic green body102and second ceramic green body110may have a print direction wherein each layer includes a lateral cross-section of second ceramic green body110. Thus, when the parts are sintered, first ceramic green body102may shrink according to a longitudinal dimension and second ceramic green body110may shrink according to a lateral dimension. It is contemplated that the difference in print directions may be associated with shrinking according to any dimension without departing from the scope of the present disclosure.

In some embodiments, the ratio of resin to ceramic in the resin-ceramic slurry of first ceramic green body102and second ceramic green body110may cause first joint surface104and second joint surface112to be pressure fit together. For example, first ceramic green body102may comprise a resin-ceramic slurry with a ratio of 1:1 (i.e., 50% resin, 50% ceramic) whereas second ceramic green body110may comprise a resin-ceramic slurry with a ratio of 49:51 (i.e., 49% resin, 51% ceramic powder). However, in some embodiments, other ratios of resin to ceramic not explicitly described herein are also contemplated. The difference in ratios may result in first ceramic green body102shrinking less than second ceramic green body110. If first joint surface104overlaps second joint surface112then the joint between first ceramic green body102and second ceramic green body110may be pressure fit due to the difference in resin to ceramic ratios.

FIG.2illustrates a first ceramic part and a second ceramic part combined to form a unitary ceramic part for some embodiments. In some embodiments, system100may combine first ceramic green body102and third ceramic green body302(as shown inFIG.3) forming unitary part202. In some embodiments, unitary part202may include any or all of the features of system100. For example, unitary part202may comprise first support structure106and second support structure114combined to form a unitary support structure. In some embodiments, unitary part202is sintered to solidify the joints between each element of system100. In some embodiments, system100may comprise a single unitary part for some embodiments.

In some embodiments, unitary part202may comprise unitary breakaway-features204. In some embodiments, unitary breakaway-features204may comprise first separable features130and second separable features132of first ceramic green body102and second ceramic green body110respectively. In some embodiments, unitary breakaway-features204are configured to separate from unitary part202such that no part of unitary support structure206may remain attached to unitary part202. In some embodiments, separating unitary breakaway-features204is achieved by applying a force to unitary support structure206. In some embodiments, a force may be applied directly to unitary breakaway-features204causing unitary support structure206to separate from unitary part202by unitary breakaway-features204. In some embodiments, unitary support structure206and unitary part202may comprise different materials. For example, unitary part202may comprise resin-ceramic slurry and unitary support structure206may comprise only resin. In some embodiments, unitary part202may comprise a ceramic-metal composite and/or unitary support structure206may comprise a resin-ceramic slurry.

In some embodiments, unitary part202may be formed by combining two or more ceramic green bodies such as first ceramic green body102and second ceramic green body110. In some embodiments, unitary part202may be formed by sintering first ceramic green body102and second ceramic green body110together. In some embodiments, first ceramic green body102and second ceramic green body110may be sintered with a plurality of other ceramic green bodies to form unitary part202.

FIG.3illustrates a system for combining a plurality of ceramic green bodies into a unitary part for some embodiments. In some embodiments, the system for combining a plurality of ceramic green bodies is exemplified by system300. In some embodiments, system300comprises first ceramic green body102, second ceramic green body110and third ceramic green body302. In some embodiments, third ceramic green body302comprises fourth joint surface306. In some embodiments, system300may be configured to join first ceramic green body102to second ceramic green body110and second ceramic green body110to third ceramic green body302.

In some embodiments, system300may comprise any amount of additional ceramic green bodies. In some embodiments, any or all of the ceramic green bodies may be configured to join to any other amount of ceramic green bodies. In some embodiments, the additional ceramic green bodies may be sintered with first ceramic green body102, second ceramic green body110, and third ceramic green body302to form a unitary ceramic part.

In some embodiments, first ceramic green body102is joined to second ceramic green body110and second ceramic green body110is joined to third ceramic green body302. In some embodiments, system300comprises a plurality of additional ceramic green bodies that may interface between first ceramic green body102and third ceramic green body302. In some embodiments, each of the ceramic green bodies may be joined to form unitary part202. In some embodiments, first ceramic green body102, second ceramic green body110, third ceramic green body302, and/or any other ceramic green bodies may be joined to form one or more unitary parts (such as unitary part202as described above).

In some embodiments, system300comprises second ceramic green body110. In some embodiments, second ceramic green body110comprises third joint surface304. In some embodiments, third joint surface304is configured to interface with another joint surface. For example, third joint surface304may be configured to interface with fourth joint surface306. In some embodiments, third joint surface304may be substantially similar to first joint surface104. For example, third joint surface304may comprise an angled surface configured to interface with another angle surface. In some embodiments, third joint surface304comprises a saw tooth edge matching a saw tooth edge of fourth joint surface306.

FIG.4illustrates a ceramic sheet applied to a damaged ceramic part for some embodiments. In some embodiments, first ceramic green body102may comprise manufacturing defects404. In some embodiments, manufacturing defects404may be a skipped layer, a layer separation, a misprinted section, and/or any other additive manufacturing error. In some embodiments, manufacturing defects404may be present only on first ceramic green body102. In some embodiments, manufacturing defects404may be present on any portion of first ceramic green body102, second ceramic green body110, and/or any other additively manufactured green bodies. In some embodiments, manufacturing defects404are repaired using a ceramic sheet.

In some embodiments, ceramic sheet406may be applied to first ceramic green body102to repair manufacturing defects404. For example, manufacturing defects404may be one or more skipped layers of first ceramic green body102. Ceramic sheet406may cover manufacturing defects404and replace the missing material by forming with the surface of first ceramic green body102as depicted inFIG.4. In some embodiments, ceramic sheet406may be applied to both first ceramic green body102and second ceramic green body110to repair manufacturing defects404present in any or all of the ceramic green bodies.

In some embodiments, manufacturing defects404are present on first support structure106and/or second support structure114. In some embodiments, manufacturing defects404present on first support structure106may be repaired using at least one ceramic sheet406. In some embodiments, ceramic sheet406may repair premature separation of first support structure106and first ceramic green body102. In some embodiments, ceramic sheet406may repair premature separation of second support structure114and second ceramic green body110. In some embodiments, first ceramic green body102and second ceramic green body110each comprise manufacturing defects404that prevent first ceramic green body102and second ceramic green body110from joining. In some embodiments, ceramic sheet406may be applied to connect first ceramic green body102and second ceramic green body110. For example, first joint surface104may comprise a flat surface and second joint surface112may comprise a flat surface. In some embodiments, first joint surface104and second joint surface112may be uneven which may cause first joint surface104and second joint surface112to separate during sintering. Ceramic sheet406may be applied across first joint surface104and second joint surface112preventing separation of first ceramic green body102and second ceramic green body110during sintering.

In some embodiments, ceramic sheet406is used to combine first ceramic green body102and second ceramic green body110. For example, first ceramic green body102and second ceramic green body110may be positioned such that first joint surface104and second joint surface112interface and a plurality of ceramic sheet406may be applied between first ceramic green body102and second ceramic green body110. Thereby connecting first ceramic green body102to second ceramic green body110. First ceramic green body102and second ceramic green body110may then be sintered combining them into unitary part202.

In some embodiments, first ceramic green body102and second ceramic green body110may be sintered with at least one ceramic sheet406connecting first ceramic green body102and second ceramic green body110. In some embodiments, ceramic sheet406may replace first joint surface104and second joint surface112in function. For example, first ceramic green body102and second ceramic green body110may not comprise first joint surface104and second joint surface112and ceramic sheet406may be used to connect them instead of the joint surfaces. In some embodiments, a single large ceramic sheet406may be used to combine first ceramic green body102and second ceramic green body110. In some embodiments, ceramic sheet406may be a plurality of smaller ceramic sheets which may be used to combine first ceramic green body102and second ceramic green body110.

In some embodiments, a plurality of ceramic sheets substantially similar to ceramic sheet406may be manufactured. In some embodiments, the plurality of ceramic sheets are layered on top of each other to form a ceramic part. For example, a first ceramic sheet may be a base layer. Then a second ceramic sheet may be applied to the first ceramic sheet to form a thicker ceramic part. Further, a third ceramic sheet may be applied to the first and second ceramic sheet to further thicken the ceramic part. This process may continue to increase the thickness of the ceramic part. In some embodiments, the plurality of ceramic sheets may be shaped to form different features of the ceramic part. For example, the first ceramic sheet may form the base of some features and the second ceramic sheet may form additional features of the ceramic part which may be further enhanced by the third ceramic sheet and so on until the ceramic part is formed in full detail.

Methods of Forming a Unitary Part

FIG.5illustrates a method for producing additively manufactured unitary parts for some embodiments. In some embodiments, the method may be performed by industrial machinery. In some embodiments, the method may be performed by industrial robotic arms. In some embodiments, the method is performed by additive manufacturing machines as described above.

Although first ceramic green body102and second ceramic green body110are described with their respective features, it is contemplated that first ceramic green body102and second ceramic green body110may comprise any form of ceramic green body that may be sintered to another ceramic green body by way of the methods described below.

In some embodiments, method500begins with step502. In some embodiments, step502may comprise additively manufacturing first ceramic green body102. In some embodiments, first ceramic green body102may comprise a ceramic material configured to shrink when heat is applied to first ceramic green body102. In some embodiments, first ceramic green body102is additively manufactured with first joint surface104. In some embodiments, first joint surface104is configured to interface with second joint surface112. In some embodiments, first joint surface104may be configured to provide frictional contact between first ceramic green body102and second ceramic green body110. In some embodiments, first joint surface104and second joint surface112may be configured to provide a frictional connection between first ceramic green body102and second ceramic green body110that remains stable during sintering. For example, first joint surface104may be scored to provide a frictional surface compared to a smooth surface. Similarly, second joint surface112may be scored to enhance the frictional surface of first joint surface104. It is contemplated that a wide variety of configurations may be employed to achieve a frictional connection between first ceramic green body102and second ceramic green body110.

In some embodiments, step502comprises additively manufacturing first ceramic green body102comprising first support structure106. In some embodiments, first support structure106may be manufactured at the same time as first ceramic green body102. In some embodiments, first support structure106may be manufactured following first ceramic green body102then attached to first ceramic green body102. In some embodiments, first support structure106may be manufactured as an element of first ceramic green body102. For example, first ceramic green body102may be additively manufactured and integrated into the structure of first ceramic green body102as described above and depicted inFIG.1.

In some embodiments, first ceramic green body102may be additively manufactured with additive manufacturing supports. For example, first ceramic green body102may comprise a floating surface that is typically impossible to additively manufacture without constructing some sort of support structure below the floating surface. Support structures may be additively manufactured along with first ceramic green body102to provide structural support to floating structures and/or to the general structure of first ceramic green body102itself. In some embodiments, the additive manufacturing supports may comprise the same material as first ceramic green body102. In some embodiments, the additive manufacturing supports may comprise a dissolvable or removable material as described above.

In some embodiments, method500comprises step504. In some embodiments, step504comprises additively manufacturing second ceramic green body110. In some embodiments, second ceramic green body110may comprises second joint surface112. In some embodiments, second joint surface112may be configured to interface with first joint surface104. In some embodiments, second joint surface112may be configured to overlap first joint surface104. In some embodiments, first joint surface104may be configured to overlap second joint surface112. In some embodiments, first joint surface104and second joint surface112may form a butt joint, lap joint, miter joint, scarf joint, mortise and tenon joint, dovetail joint, tongue and groove joint, tapered dovetail joint, or any other such joint. In some embodiments, first joint surface104may be joined to a third joint surface distinct from second joint surface112.

In some embodiments, step504comprises additively manufacturing second ceramic green body110comprising second joint surface112. In some embodiments, second joint surface112is manufactured at the same time as second ceramic green body110. In some embodiments, second joint surface112may be manufactured following second ceramic green body110. In some embodiments, second joint surface112may be manufactured as an element of second ceramic green body110. For example, second ceramic green body110may be additively manufactured and integrated into the structure of second ceramic green body110as described above and depicted inFIG.1. In some embodiments, the elements of first ceramic green body102and second ceramic green body110may be additively manufactured separately then connected before sintering.

In some embodiments, second ceramic green body110may be additively manufactured with additive manufacturing supports. For example, second ceramic green body110may comprise a floating surface that is typically impossible to additively manufacture without constructing some sort of support structure below the floating surface. Support structures may be additively manufactured along with second ceramic green body110to provide structural support to floating structures and/or to the general structure of second ceramic green body110itself. In some embodiments, the additive manufacturing supports may comprise the same material as second ceramic green body110. In some embodiments, the additive manufacturing supports may comprise a dissolvable or removable material as described above.

In some embodiments the method500comprises step506. In some embodiments, step506comprises joining first ceramic green body102and second ceramic green body110using the first and second joint surface. In some embodiments, first ceramic green body102and second ceramic green body110are joined by automated machinery. In some embodiments, first ceramic green body102and second ceramic green body110are configured to be joined by robotic assembly lines. In some embodiments, first ceramic green body102and second ceramic green body110are joined during the sintering process. In some embodiments, first ceramic green body102and second ceramic green body110are joined prior to the sintering process. In some embodiments, first ceramic green body102and second ceramic green body110is positioned such that the first and second joint surface interface with each other. In some embodiments first ceramic green body102and second ceramic green body110may be interfaced by hand. In some embodiments, first ceramic green body102and second ceramic green body110may be interfaced partially by machine and partially by hand.

In some embodiments, method500may comprise step508. In some embodiments, step508may comprise combining first ceramic green body102and second ceramic green body110to form unitary part202using sintering. In some embodiments, first ceramic green body102and second ceramic green body110may be sintered in a kiln. In some embodiments, sintering causes first ceramic green body102and second ceramic green body110to shrink. In some embodiments, the shrinking caused by sintering first ceramic green body102and second ceramic part may provide structural support to unitary part202formed by first ceramic green body102and the second part. In some embodiments, unitary part202may be sintered using selective laser sintering. In some embodiments, first ceramic green body102and second ceramic green body110may be partially sintered using selective laser sintering prior to sintering the rest of first ceramic green body102and second ceramic green body110.

In some embodiments, step508may comprise increasing the density of first ceramic green body102and second ceramic green body110such that unitary part202may have a higher density than first ceramic green body102and second ceramic green body110. In some embodiments, the increase in density is caused by the removal of resin during sintering. In some embodiments, the increase in density may be a result of thermodynamic expansion in the ceramic powder of the resin-ceramic slurry.

In some embodiments, method500comprises step510. In some embodiments, step510comprises separating unitary part202from unitary support structure206. In some embodiments, unitary part202a separated from unitary support structure206by applying a force to unitary support structure206. In some embodiments, the force applied to unitary support structure206causes unitary breakaway-features204to break, thereby separating unitary part202and unitary support structure206. In some embodiments, step510comprises separating additional support structures from unitary part202. In some embodiments, step510may not be performed and unitary support structure206may remain attached to unitary part202.

In some embodiments, method500comprises additional steps. In some embodiments, method500comprises curing the resin-ceramic slurry used to additively manufacture first ceramic green body102and second ceramic green body110. In some embodiments, curing the resin-ceramic slurry is done using UV-light, chemical curing, heat curing, or any other such curing process.

FIG.6illustrates an embodiment of a method of additively manufacturing unitary ceramic parts such as method600. In some embodiments, method600may be conducted via machinery. In some embodiments, method600may be performed by robotics such as robotic assembly lines, robotic manufacturing arms, or any other such robotic device. In some embodiments, method600begins with step602.

In some embodiments, step602comprises additively manufacturing first ceramic green body102. The first ceramic part may include first support structure106additively manufactured in conjunction with manufacturing first ceramic green body102. In some embodiments, first ceramic green body102and first support structure106may be integrated together such that first support structure106is integrated into first ceramic green body102. In some embodiments, first support structure106is configured to prevent flexion of first ceramic green body102during sintering. For example, first support structure106may extend between first edge122aof the ceramic part to second edge122bof first ceramic green body102part such that first support structure106provides a resistance to flexion forces causing the first side to shrink towards the second side.

In some embodiments, method600continues with step604. Step604may be directed to additively manufacturing Second ceramic green body110. Second ceramic green body110may include second support structure114additively manufactured in conjunction with second ceramic green body110. In some embodiments, second ceramic green body110and second support structure114may be integrated together such that second support structure114may be integrated into second ceramic green body110. In some embodiments, second support structure114may be configured to prevent flexion of second ceramic green body110during sintering. For example, second support structure114may be configured to extend between first side124aof second ceramic green body110to second side124bof second ceramic green body110such that second support structure114provides a resistance to flexion forces causing first side124ato shrink towards second side124b.

In some embodiments, method600comprises step606. Step606may be directed to positioning first ceramic green body102and second ceramic green body110such that first joint surface104and second joint surface112are connected. In some embodiments, first joint surface104and second joint surface112may comprise matching features configured to be connected such that first joint surface104and second joint surface112are combined by sintering. In some embodiments, first joint surface104and second joint surface112may be connected by applying a slurry mixture to first joint surface104and second joint surface112then interfacing the joining surfaces such that the slurry mixture serves as an adhesive material that may be sintered into the structure of unitary part202.

In some embodiments, method600comprises step608. Step608may comprise sintering first ceramic green body102and second ceramic green body110such that first ceramic green body102and second ceramic green body110combine forming unitary part202. In some embodiments, unitary part202may have all the features of first ceramic green body102and second ceramic green body110. In some embodiments, some of the features of first ceramic green body102and second ceramic green body110are lost during sintering. For example, first ceramic green body102and second ceramic green body110may comprise joining surfaces that, when first ceramic green body102and second ceramic green body110are combined and sintered, become indistinguishable from the surface of the unitary part202and are permanently joined together thereby removing their ability to further join surfaces. In some embodiments, unitary part202may be structurally supported by the structure of the first and second joining surfaces. For example, first ceramic green body102having the first joining surface may be formed with a first print direction and second ceramic green body110having the second joining surface may be formed with a second print direction. First joint surface104and second joint surface112may be interfaced providing a cross-hatched structure of the print directions thereby providing a greater resistance to forces in either direction.

In some embodiments, first ceramic green body102and second ceramic green body110may comprise first joint surface104and second joint surface112respectively. In some embodiments, first joint surface104and second joint surface112may be configured to interface with each other. For example, first joint surface104may comprise an interlocking sawtooth pattern matching a corresponding interlocking sawtooth pattern of second joint surface112such that first ceramic green body102and second ceramic green body110may be joined by first joint surface104and second joint surface112. In some embodiments, first support structure106and first support joint surface second support structure114may comprise first support joint surface108and second support joint surface116. In some embodiments first support joint surface108and second support joint surface116may be configured to interface with each other. For example, first support joint surface108may comprise a set of square teeth matching a corresponding set of square teeth present on second support joint surface116such that first support joint surface108and second support joint surface116may be joined together.

In some embodiments, first support structure106and the second support structure may comprise materials different from the ceramics used for first ceramic green body102and second ceramic green body110. In some embodiments, first ceramic green body102may comprise a resin-ceramic slurry mixture. In some embodiments, the resin-ceramic slurry mixture is configured to shrink based upon the ratio of resin to ceramic. For example, the resin-ceramic slurry may comprise 50% resin and 50% ceramic such that the resin-ceramic slurry has an expected shrink factor of 50%. i.e., the overall size of the part is expected to shrink by 50%. In some embodiments, the resin-ceramic slurry may have an expected shrink factor of 15% based upon a 15% resin, 85% ceramic mixture. In some embodiments, the resin is removed from first ceramic green body102by the sintering process.

In some embodiments, first support structure106and second support structure114may comprise resin-ceramic slurry having a different resin to slurry ratio than first ceramic green body102and second ceramic green body110. In some embodiments, the resin-ceramic slurry of first support structure106and second support structure114may be configured to have a lower shrink factor (i.e., ratio of resin to ceramic) than the resin-ceramic slurry used in first ceramic green body102and second ceramic green body110. First support structure106and second support structure114may shrink less than first ceramic green body102and second ceramic green body110thereby forming unitary support structure206during sintering. In some embodiments, first support structure106and second support structure114may be configured to shrink more than first ceramic green body102and second ceramic green body110. For example, first support structure106and second support structure114may have a resin-ceramic slurry with a shrink factor of 30% while first ceramic green body102and second ceramic green body110may have a shrink factor of 50%.

In some embodiments, first support structure106may be configured to interface with second support structure114such that first support structure106and second support structure114form a unitary support structure. For example, in some embodiments, first support structure106may have a set of square teeth configured to interface with a corresponding set of square teeth present on second support structure114. In some embodiments, the first joint surface of first ceramic green body102and the second joint surface of second ceramic green body110may be interfaced in conjunction with the first support joint surface and the second support joint surface.

In some embodiments, first ceramic green body102and second ceramic green body110may be sintered with first support structure106and second support structure114. In some embodiments, first support structure106and second support structure114may be configured to provide structural support during sintering. For example, first support structure106and second support structure114may be configured to brace a first side of first ceramic green body102and second ceramic green body110against flexion forces of a second opposite side of first ceramic green body102and second ceramic green body110. In some embodiments, first support structure106and second support structure114are unified to form a unitary support structure. In some embodiments, the unitary support structure may provide structural support to the unitary ceramic part during sintering.

In some embodiments, first support structure106and second support structure114may comprise first separable features130and second separable features132configured to allow first support structure106and second support structure114to be separated from the unitary ceramic part after sintering. In some embodiments, first support structure106and second support structure114combine to form a unitary support structure. In some embodiments, first separable features130of first support structure106and second separable features132of second support structure114are integrated into the unitary support structure. In some embodiments, first separable features130and second separable features132integrated into the unitary support structure may allow unitary support structure206to be separated from unitary part202. In some embodiments, first separable features130and second separable features132may comprise a central breaking line configured to allow first support structure106and second support structure114to be broken along the central breaking line such that first support structure106and second support structure114may be separated from first ceramic green body102and second ceramic green body110without damage. For example, first support structure106and second support structure114may have a low percentage contact area between the support structure and first ceramic green body102and second ceramic green body110. The first and second support structure may only contact 5-25%, 5-20%, 5-15%, or 5-10% of the surface of first ceramic green body102and second ceramic green body110such that breaking the joint between the support structures and the ceramic parts may be unlikely to damage first support structure106and second support structure114.

FIG.7illustrates a method for additively manufacturing a unitary ceramic part for some embodiments. In some embodiments, the method ofFIG.7may be exemplified by method700. In some embodiments, method700may be performed by industrial machinery. In some embodiments, method700may be performed by industrial robotics.

In some embodiments, method700comprises step702. Step702may comprise manufacturing a first ceramic part. In some embodiments, step702may comprise manufacturing first ceramic green body102. In some embodiments, step702may comprise manufacturing first ceramic green body102with first support structure106absent. In some embodiments, step702comprises manufacturing first ceramic green body102with first support structure106and first support joint surface108absent. In some embodiments, step702comprises manufacturing a ceramic part similar to first ceramic green body102but comprising a different shape. In some embodiments, step702comprises manufacturing any ceramic green body regardless of shape.

In some embodiments, method700comprises step704. In some embodiments, step704may comprise manufacturing a second ceramic part. In some embodiments, step704may comprise manufacturing second ceramic green body110. In some embodiments, step704may comprise manufacturing second ceramic green body110with second joint surface112. In some embodiments, step704may comprise manufacturing second ceramic green body110as described above. In some embodiments, step704may comprise manufacturing second ceramic green body110with second joint surface112, second support structure114, and/or second support joint surface116, or any combination thereof absent. In some embodiments, step704comprises manufacturing second ceramic green body110with additional features not shown. In some embodiments, step704comprises manufacturing second ceramic green body110using stereolithography, fused deposition modeling, or any other such additive manufacturing technique. In some embodiments, step704comprises manufacturing second ceramic green body110used traditional manufacturing such as clay forming, sculpting, or heat pressing.

In some embodiments, method700comprises step706. In some embodiments, step706comprises connecting first ceramic green body102and second ceramic green body110together using first joint surface104and second joint surface112. In some embodiments, connecting first ceramic green body102and second ceramic green body110comprises positioning first ceramic green body102and second ceramic green body110such that first joint surface104interfaces with second joint surface112. In some embodiments, step706comprises positioning first ceramic green body102and second ceramic green body110such that first ceramic green body102contacts second ceramic green body110.

In some embodiments, step706comprises applying a layer of the resin-ceramic slurry between first ceramic green body102and second ceramic green body110before connecting. In some embodiments, applying the later of resin-ceramic slurry may provide a layer of sinterable adhesive that hardens into the same material as first ceramic green body102and second ceramic green body110when sintered.

In some embodiments, method700comprises step708. In some embodiments, step708comprises sintering first ceramic green body102and second ceramic green body110. In some embodiments, step708comprises sintering first ceramic green body102and first support joint surface108with an uncured layer of resin-ceramic slurry between first joint surface104and second joint surface112. In some embodiments, step708comprises selectively sintering portions of first ceramic green body102and second ceramic green body110. For example, first joint surface104and second joint surface112may be selectively sintered using a sintering technique such as selective laser sintering to join first ceramic green body102and second ceramic green body110. Then the rest of first ceramic green body102and second ceramic green body110may be sintered using traditional methods.

FIG.8illustrates a method for repairing a damaged ceramic green body for some embodiments. In some embodiments, first ceramic green body102may comprise manufacturing defects causing first ceramic green body102to be damaged. In some embodiments, first ceramic green body102may have poor printing quality. In some embodiments, the damaged part may have missing layers, bed separation, or any other form of print defect found in additive manufacturing.

In some embodiments, method800begins with step802. Step802may comprise additively manufacturing ceramic sheet406as described above. Ceramic sheet406may comprise a thin sheet of resin-ceramic slurry. For example, ceramic sheet406may comprise a resin-ceramic sheet 5-10 millimeters thick. It is noted that ceramic sheet406may comprise any thickness without departing from the scope of the present disclosure. In some embodiments, ceramic sheet406may comprise only few thin layers of resin-ceramic slurry. In some embodiments, ceramic sheet406may be configured to have a resin to ceramic ratio less than the additively manufactured part.

In some embodiments, method800comprises step804. Step804may comprise applying ceramic sheet406to first ceramic green body102. In some embodiments, ceramic sheet406may be a plurality of ceramic repair sheets which may be applied to first ceramic green body102. In some embodiments, ceramic sheet406is additively manufactured according to a print direction. In some embodiments, ceramic sheet406may be applied to first ceramic green body102such that first ceramic green body's102print direction may be perpendicular to the print direction of ceramic sheet406.

In some embodiments, a thin layer of uncured resin-ceramic slurry may be applied to ceramic sheet406and first ceramic green body102to improve adhesion between ceramic sheet406and first ceramic green body102. In some embodiments, ceramic sheet406may be applied to first ceramic green body102. In some embodiments, a plurality of additional ceramic sheets may be applied to increase rigidity, provide additional repair, or provide a different appearance. In some embodiments, the surface of ceramic sheet406is different than the surface of first ceramic green body102. In some embodiments, ceramic sheet406may be applied to first ceramic green body102to change the surface texture of first ceramic green body102. In some embodiments, ceramic sheet406may be applied to an un-damaged ceramic part. In some embodiments, the un-damaged ceramic part may be covered in the plurality of ceramic sheets such that the entire surface of the un-damaged ceramic part may be changed. In some embodiments, the surface of ceramic sheet406may comprise a smooth surface. In some embodiments, the surface of ceramic sheet406may comprise a rough surface, a textured surface, a patterned surface, a ridged surface, or any other such surface finish.

In some embodiments, ceramic sheet406is malleable and bendable. In some embodiments, ceramic sheet406may conform around the contours of first ceramic green body102. In some embodiments, ceramic sheet406may be additively manufactured to have a shape matching the contours of first ceramic green body102. In some embodiments, ceramic sheet406may be applied to first ceramic green body102using a robotic appendage. In some embodiments, the first ceramic sheet may be vacuum formed to the contours of first ceramic green body102.

In some embodiments, method800comprises step806. In some embodiments, step806comprises sintering first ceramic green body102and first ceramic green body102to form unitary part202. In some embodiments, the plurality of ceramic sheets may be sintered with first ceramic green body102to form unitary part202. In some embodiments, first ceramic green body102may be partially sintered when ceramic sheet406is applied. In some embodiments, ceramic sheet406is applied before sintering. In some embodiments, ceramic sheet406may be applied during sintering. In some embodiments, the plurality of ceramic sheets may be applied prior to sintering. In some embodiments, the plurality of ceramic sheets may be applied after sintering and then first ceramic green body102may be re-sintered. In some embodiments, the plurality of sheets may be applied to first ceramic green body102during sintering.

In some embodiments, ceramic sheet406may be configured to provide additional structural rigidity to the damaged part. For example, ceramic sheet406may have a print direction opposing the print direction of the damaged part. The difference in print directions may (e.g., cross hatching) may provide structural rigidity. In some embodiments, ceramic sheet406may provide structural rigidity simply by increasing the thickness of the structure. In some embodiments, ceramic sheet406may restore the thickness of weakened sections of the ceramic body to their original thickness such that structural rigidity is not lost. In some embodiments, ceramic sheet406may be used to seal holes in the surface of first ceramic green body102. For example, first ceramic green body102may be manufactured with missing sections. Ceramic sheet406may be arranged to cover or seal the missing sections such that first ceramic green body102may still be used for its intended purpose. In some embodiments, a layer of the resin-ceramic slurry may be applied before applying ceramic sheet406sheets to both provide adhesive action and provide seal around the missing sections of first ceramic green body102. In some embodiments, ceramic sheet406comprises a plurality of ceramic sheets.

In some embodiments, ceramic sheet406is applied to the damaged part before the part is sintered to a second ceramic part. For example, first ceramic green body102may be a first part. Ceramic sheet406may be applied to first ceramic green body102preparing first ceramic green body102for being combined into unitary part202. First ceramic green body102may be damaged and may be positioned such that first joint surface104interfaces with second joint surface112of second ceramic green body110. First ceramic green body102, ceramic sheet406, and second ceramic green body110may then be sintered to form a unitary part202.

In some embodiments, second ceramic green body110may also be a damaged ceramic part. In some embodiments, ceramic sheet406is applied to second ceramic green body110to repair defects or damage to the part. For example, as described above, ceramic sheet406may be applied to first ceramic green body102to cover or seal missing sections of first ceramic green body102. In some embodiments, a layer of resin-ceramic slurry is applied to second ceramic green body110before applying ceramic sheet406such that the slurry mixture may serve as an adhesive agent and a seal around the missing sections of second ceramic green body110.

In some embodiments, first ceramic green body102and the second ceramic damaged part may then be sintered to form a unitary ceramic part. In some embodiments, first ceramic green body102and second ceramic green body110may be repaired by applying ceramic sheet406to the first and second damaged ceramic part prior to sintering. In some embodiments, the first and second damaged ceramic part may comprise joining surfaces that may be interfaced prior to sintering. In some embodiments, ceramic sheet406may be applied to the first and second damaged ceramic part such that the joining surfaces, while interfaced, are covered by ceramic sheet406thereby improving the connection between first ceramic green body102and second ceramic green body110.

System for Combining Additively Manufactured Ceramic Parts

FIG.9illustrates method900for additively manufacturing a unitary ceramic part for some embodiments. In some embodiments, method900is directed to additively manufacturing a ceramic part larger than the available print volume. For example, method900may be employed to additively manufacture a cylinder having a radius of 5 in and a height of 10 inches on a print bed having a 5×5×5 inch print volume (i.e., 125 cubic-inch print volume). In some embodiments, method900may be directed to increasing the size of a first ceramic part (such as first ceramic green body102as described above) by joining the first ceramic part to a second ceramic part (such as second ceramic green body110as described above).

In some embodiments, method900begins with step902. Step902may comprise manufacturing first ceramic green body102. In some embodiments, step902comprises additively manufacturing first ceramic green body102with first joint surface104. In some embodiments, step902comprises manufacturing first ceramic green body102with first support structure106. In some embodiments, step902comprises additively manufacturing first ceramic green body102with first support structure106and first support joint surface108. In some embodiments, step902comprises manufacturing first ceramic green body102with first joint surface104and a plurality of other joint surfaces integrated into first ceramic green body102.

In some embodiments, method900comprises step904. In some embodiments, step904comprises additively manufacturing second ceramic green body110. In some embodiments, step904comprises additively manufacturing second ceramic green body110wherein second ceramic green body110comprises second joint surface112, second support structure114, second support joint surface116, or any combination thereof. In some embodiments, step904may be substantially similar to step902wherein first ceramic green body102may be replaced by second ceramic green body110.

In some embodiments, method900comprises step906. In some embodiments, step906comprises additively manufacturing a ceramic sheet. In some embodiments, the ceramic sheet may be substantially similar to ceramic sheet406as described above. In some embodiments, step906may comprise additively manufacturing a plurality of ceramic sheets substantially similar to ceramic sheet406. In some embodiments, step906may comprise additively manufacturing ceramic sheet406using stereolithography, fused deposition modeling, selective laser sintering, or any other such additive manufacturing technique.

In some embodiments, method900comprises step908. In some embodiments, step908comprises positioning first ceramic green body102and second ceramic green body110to form a joint between first ceramic green body102and second ceramic green body110. In some embodiments, the joint is formed by first joint surface104interfacing with second joint surface112. In some embodiments, first joint surface104and second joint surface112are absent and the joint may be formed by abutting first ceramic green body102and second ceramic green body110. In some embodiments, a layer of the resin-ceramic slurry is applied between first ceramic green body102and second ceramic green body110to act as an adhesive during sintering. In some embodiments, the resin-ceramic slurry between first ceramic green body102and second ceramic green body110is sintered to form a connection between first ceramic green body102and second ceramic green body110.

In some embodiments, method900comprises step910. In some embodiments, step910comprises applying at least one ceramic sheet406across the joint between first ceramic green body102and second ceramic green body110. In some embodiments, a plurality of ceramic sheets406may be applied across the joint formed by first ceramic green body102and second ceramic green body110. In some embodiments, a layer of ceramic-slurry may be applied to first ceramic green body102and second ceramic green body110before ceramic sheet406is applied. In some embodiments, an uncured layer of resin-ceramic slurry may be applied to ceramic sheet406before ceramic sheet406is applied to first ceramic green body102and second ceramic green body110. In some embodiments, first ceramic green body102and second ceramic green body110may not abut and ceramic sheet406may be applied across a gap between first ceramic green body102and second ceramic green body110.

In some embodiments, method900comprises step912. In some embodiments, step912comprises sintering first ceramic green body102, second ceramic green body110, and ceramic sheet406to form unitary part202. In some embodiments, step912comprises sintering only the connection between first ceramic green body102and second ceramic green body110. For example, first ceramic green body102and second ceramic green body110may be joined by ceramic sheet406. A selective laser sintering process may sinter only ceramic sheet406and the portions of first ceramic green body102and second ceramic green body110covered by ceramic sheet406. Thus, first ceramic green body102and second ceramic green body110may be connected using selective laser sintering.

Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.