# US 12,005,504 B2 · Method for fabricating a three-dimensional metal part using a conformable fugitive material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,005,504 B2 - Document ID: US12005504B2 - Status: Granted - Kind: B2 - Application number: 17/406,698 - Filed: 2021-08-19 - Published: 2022-02-24 - Granted: 2024-06-11 - Earliest claimed: 2020-08-24 - Assignees: Kennametal Inc. - Applicants: Kennametal Inc. - Inventors: Paul D. Prichard - Web page: https://patentgrep.com/patent/US12005504B2 ## CPC - B22F 3/04: by applying fluid pressure {, e.g. by cold isostatic pressing [CIP]} - B22F 10/10: Formation of a green body - B22F 10/14: by jetting of binder onto a bed of metal powder - B22F 10/60: Treatment of workpieces or articles after build-up - B22F 10/66: by mechanical means - B33Y 10/00: Processes of additive manufacturing - B33Y 40/20: Post-treatment, e.g. curing, coating or polishing - B33Y 80/00: Products made by additive manufacturing - B22F 2005/001: {Cutting tools, earth boring or grinding tool other than table ware} - B22F 2998/10: Processes characterised by the sequence of their steps - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - C22C 29/00: Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides {(C22C26/00 takes precedence)} - Y02P 10/25: Process efficiency - 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 - C22C: ALLOYS (treatment of alloys C21D, C22F) - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract The present invention is directed towards a method for fabricating a three-dimensional metal, ceramic, and/or cermet part, the method comprising forming the three-dimensional metal, ceramic, and/or cermet part by an additive manufacturing technique; encapsulating the three-dimensional metal, ceramic, and/or cermet part in a conformable fugitive material to form an encapsulated three-dimensional metal, ceramic, and/or cermet part; and cold isostatic pressing the encapsulated three-dimensional metal, ceramic, and/or cermet part with pressurized incompressible fluid that contacts the conformable fugitive material. Also disclosed are three-dimensional metal, ceramic, and/or cermet parts fabricated according to said method. ## Claims ### Claim 1 A method for fabricating a three-dimensional metal, ceramic, and/or cermet part, the method comprising: (a) forming the three-dimensional metal, ceramic, and/or cermet part by an additive manufacturing technique; (b) encapsulating the three-dimensional metal, ceramic, and/or cermet part in a conformable fugitive material to form an encapsulated three-dimensional metal, ceramic, and/or cermet part, wherein encapsulating the three-dimensional metal, ceramic, and/or cermet part in a conformable fugitive material comprises applying a coating by physical vapor deposition; and (c) cold isostatic pressing the encapsulated three-dimensional metal, ceramic, and/or cermet part with pressurized incompressible fluid that contacts the conformable fugitive material. ### Claim 2 (depends on 1) The method of claim 1, wherein the additive manufacturing process comprises a process for forming a metal, ceramic, and/or cermet powder and optionally a binder into the three-dimensional metal, ceramic, and/or cermet part. ### Claim 3 (depends on 1) The method of claim 1, wherein the additive manufacturing process comprises at least one of binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, sheet lamination, and/or vat photopolymerization. ### Claim 4 (depends on 1) The method of claim 1, wherein the conformable fugitive material comprises an organic polymeric material. ### Claim 5 (depends on 4) The method of claim 4, wherein the organic polymeric material comprises a thermoplastic material. ### Claim 6 (depends on 4) The method of claim 4, wherein the organic polymeric material comprises an elastomeric material. ### Claim 7 (depends on 4) The method of claim 4, wherein the organic polymeric material comprises paraffin wax. ### Claim 8 (depends on 1) The method of claim 1, wherein the coating has a thickness of less than 1 mm. ### Claim 9 (depends on 1) The method of claim 1, wherein the cold isostatic pressing provides a pressure of 10 ksi to 50 ksi. ### Claim 10 (depends on 1) The method of claim 1, wherein the pressurized incompressible fluid comprises water, oil, or a water/oil emulsion. ### Claim 11 (depends on 1) The method of claim 1, further comprising removing the conformable fugitive material from the encapsulated three-dimensional metal, ceramic, and/or cermet part after compressing the encapsulated three-dimensional metal, ceramic, and/or cermet part. ### Claim 12 (depends on 11) The method of claim 11, wherein removing the conformable fugitive material comprises a chemical, thermal, or mechanical process. ### Claim 13 (depends on 11) The method of claim 11, wherein removing the conformable fugitive material comprises heating the encapsulated three-dimensional metal, ceramic, and/or cermet part to a temperature above the melting point of the conformable fugitive material. ### Claim 14 (depends on 11) The method of claim 11, wherein removing the conformable fugitive material comprises heating the encapsulated three-dimensional metal, ceramic, and/or cermet part to a temperature above the vaporization temperature of the conformable fugitive material. ### Claim 15 (depends on 1) The method of claim 1, further comprising sintering the three-dimensional metal, ceramic, and/or cermet part. ### Claim 16 (depends on 1) The method of claim 1, wherein the three-dimensional metal, ceramic, and/or cermet part comprises a metal cutting tool. ### Claim 17 (depends on 16) The method of claim 16, wherein the metal cutting tool comprises internal cooling passages. ### Claim 18 A method for fabricating a three-dimensional metal, ceramic, and/or cermet part, the method comprising: (a) forming the three-dimensional metal, ceramic, and/or cermet part by an additive manufacturing technique; (b) encapsulating the three-dimensional metal, ceramic, and/or cermet part in a conformable fugitive material to form an encapsulated three-dimensional metal, ceramic, and/or cermet part, wherein encapsulating the three-dimensional metal, ceramic, and/or cermet part in a conformable fugitive material comprises placing the three-dimensional metal, ceramic, and/or cermet part in a mold and pouring the conformable fugitive material in a molten state into the mold to encapsulate the three-dimensional metal, ceramic, and/or cermet part in the conformable fugitive material; and (c) cold isostatic pressing the encapsulated three-dimensional metal, ceramic, and/or cermet part with pressurized incompressible fluid that contacts the conformable fugitive material. ### Claim 19 A method for fabricating a three-dimensional metal, ceramic, and/or cermet part, the method comprising: (a) forming the three-dimensional metal, ceramic, and/or cermet part by an additive manufacturing technique; (b) encapsulating the three-dimensional metal, ceramic, and/or cermet part in a conformable fugitive material to form an encapsulated three-dimensional metal, ceramic, and/or cermet part; (c) cold isostatic pressing the encapsulated three-dimensional metal, ceramic, and/or cermet part with pressurized incompressible fluid that contacts the conformable fugitive material; and (d) removing the conformable fugitive material from the encapsulated three-dimensional metal, ceramic, and/or cermet part after compressing the encapsulated three-dimensional metal, ceramic, and/or cermet part, wherein the conformable fugitive material removed from the encapsulated three-dimensional metal, ceramic, and/or cermet part is collected and used for encapsulating a newly formed three-dimensional metal, ceramic, and/or cermet part in the conformable fugitive material.