# US 10,479,023 B2 · Method for producing void-free additively manufactured components > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,479,023 B2 - Document ID: US10479023B2 - Status: Granted - Kind: B2 - Application number: 15/922,049 - Filed: 2018-03-15 - Published: 2018-07-19 - Granted: 2019-11-19 - Earliest claimed: 2014-05-08 - Assignees: United Technologies Corporation - Applicants: United Technologies Corporation - Inventors: Sergey Mironets - Web page: https://patentgrep.com/patent/US10479023B2 ## CPC - B23P 15/00: Making specific metal objects by operations not covered by a single other subclass or a group in this subclass - B23P 17/00: Metal-working operations, not covered by a single other subclass or another group in this subclass - B29C 64/141: using only solid materials - B29C 64/147: using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object - B29C 65/02: by heating, with or without pressure - B22F 2003/1051: {by electric discharge} - B23P 2700/12: Laminated parts - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 80/00: Products made by additive manufacturing - Y10T 156/1074: Separate cutting of separate sheets or webs - Y10T 156/12: Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing - B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of additive manufacturing of a component includes cutting a plurality of sheets, each sheet corresponding to a respective cross-section of the component, tack welding the sheets to one another to form a stack, arranging the stack in a mold, and spark plasma sintering the tack-welded stack of sheets to reduce vacancies and dislocations between adjacent sheets of the stack. ## Claims ### Claim 1 A spark plasma sintering system comprising: a mold configured to surround a stack of tack-welded sheets; a top platen and a bottom platen configured to cooperate to apply a pressure to the stack of tack-welded sheets; a first electrode and a second electrode configured to cooperate to apply a direct current through the stack of tack-welded sheets; and an induction heating coil configured to encircle the stack of tack-welded sheets. ### Claim 2 (depends on 1) The spark plasma sintering system of claim 1, wherein the first electrode and the second electrode each comprise: a copper layer; a brass layer arranged between the copper layer and the stack of tack-welded sheets; and a graphite layer arranged between the brass layer and the stack of tack-welded sheets. ### Claim 3 (depends on 1) The spark plasma sintering system of claim 1, wherein the mold is a ring mold configured to circumscribe the stack of tack-welded sheets. ### Claim 4 (depends on 3) The spark plasma sintering system of claim 3, wherein the ring mold is configured to maintain contours of the stack of tack-welded sheets. ### Claim 5 (depends on 3) The spark plasma sintering system of claim 3, wherein the top and bottom platens are configured to engage top and bottom surfaces of the ring mold. ### Claim 6 (depends on 3) The spark plasma sintering system of claim 3, wherein the ring mold is configured to maintain a vacuum seal around the stack of tack-welded sheets. ### Claim 7 (depends on 3) The spark plasma sintering system of claim 3, wherein the ring mold is oversized with respect to the stack of tack-welded sheets. ### Claim 8 (depends on 3) The spark plasma sintering system of claim 3, wherein the top and bottom platens are configured to move within the ring mold. ### Claim 9 (depends on 1) The spark plasma sintering system of claim 1, further comprising: a high voltage source coupled to the top and bottom platens. ### Claim 10 (depends on 1) The spark plasma sintering system of claim 1, wherein the high voltage source is configured to supply the direct current through the stack of tack-welded sheets so as to cause spark plasma sintering of the stack of tack-welded sheets. ### Claim 11 (depends on 1) The spark plasma sintering system of claim 1, further comprising: a powder material arranged between the mold and the stack of tack-welded sheets. ### Claim 12 (depends on 11) The spark plasma sintering system of claim 11, wherein the powder material is a conductive powder. ### Claim 13 (depends on 11) The spark plasma sintering system of claim 11, wherein the powder material is graphite powder. ### Claim 14 (depends on 1) The spark plasma sintering system of claim 1, wherein the induction heating coil is further configured to generate a magnetic field in the stack of tack-welded sheets. ### Claim 15 (depends on 1) The spark plasma sintering system of claim 1, wherein the induction heating coil is further configured to generate heat in the stack of tack-welded sheets so as to cause spark plasma sintering of the stack of tack-welded sheets. ### Claim 16 (depends on 1) The spark plasma sintering system of claim 1, further comprising a laminated object cutting system that includes: a feed roll; a take-up roll; and a sheet cutter, wherein the feed roll and the take-up roll are configured to cooperative so as to move sheet material in relation to the sheet cutter. ### Claim 17 (depends on 16) The spark plasma sintering system of claim 16, wherein the sheet cutter is a laser configured to direct an optical beam at the sheet material. ### Claim 18 (depends on 16) The spark plasma sintering system of claim 16, wherein the sheet cutter is configured to use water jets to cut the sheet material. ### Claim 19 (depends on 16) The spark plasma sintering system of claim 16, wherein the sheet cutter is configured to use an electron beam to cut the sheet material.