US 12,186,935 B1Granted

Joining additively manufactured ceramic green bodies

AssigneeHoneywell Federal Manufacturing & Technologies, LLC

InventorsBrandon Cox, Joseph Reyes, Connor Lane Chadbourne, Alexandra Dzubak, Thomas Canfield

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Abstract

Methods and systems for additively manufacturing a unitary ceramic part and repairing damaged ceramic parts including additively manufacturing a first ceramic green body having a joint surface and a second ceramic green body having a joint surface, wherein the joint surfaces are configured to be interfaced. The first ceramic green body and the second ceramic green body are sintered to form the unitary part. Additional ceramic green bodies may be connected and sintered to form the unitary part. The ceramic green bodies may have defects or may be damaged. A ceramic sheet may be manufactured and applied to the ceramic green bodies to repair the defects or damage. The ceramic sheet may be sintered with the ceramic green bodies to form the unitary part.

Claims13

Dependent claims

A method for producing a unitary part, the method comprising:

additively manufacturing a first ceramic part comprising a first joint surface and a first support structure, wherein the first joint surface comprises a first lipped edge integrated within a first body of the first ceramic part, the first lipped edge comprising a different circumference than a first outer surface of the first body of the first ceramic part;
additively manufacturing a second ceramic part comprising a second joint surface and a second support structure, wherein the second joint surface comprises a second lipped edge integrated within a second body of the second ceramic part, the second lipped edge comprising a similar circumference as a second outer surface of the second body of the second ceramic part;
positioning the first ceramic part and the second ceramic part such that the first joint surface contacts the second joint surface by overlapping the first lipped edge with the second lipped edge such that a continuous external surface is created between the first ceramic part and the second ceramic part and such that the first support structure contacts the second support structure;
sintering the first joint surface to the second joint surface such that the first lipped edge overlapping the second lipped edge are combined and such that the first support structure is combined to the second support structure to form the unitary part comprising the first ceramic part and the second ceramic part;
and
separating the first support structure and the second support structure from the unitary part.

3 more elements

A method for producing a unitary part comprising a first additively manufactured ceramic part comprising:

at least one first joint surface, wherein the at least one first joint surface comprises a first lipped edge integrated within a first body of the first additively manufactured ceramic part, the first lipped edge comprising a different circumference than a first outer surface of the first body of the first additively manufactured ceramic part;
a first support structure;
and at least one first support joint surface;
and a second additively manufactured ceramic part comprising:
at least one second joint surface connected to the at least one first joint surface of the first additively manufactured ceramic part, wherein the at least one second joint surface comprises a second lipped edge integrated within a second body of the second additively manufactured ceramic part, the second lipped edge comprising a similar circumference as a second outer surface of the second body of the second additively manufactured ceramic part;
a second support structure;
and a second support joint surface connected to the at least one first support joint surface, the method comprising:
additively manufacturing the first additively manufactured ceramic part;
additively manufacturing the second additively manufactured ceramic part;
positioning the first additively manufactured ceramic part and the second additively manufactured ceramic part such that the first lipped edge contacts the second lipped edge by overlapping the first lipped edge of the at least one first joint surface with the second lipped edge of the at least one second joint surface such that a continuous external surface is created between the first additively manufactured ceramic part and the second additively manufactured ceramic part and such that the first support structure contacts the second support structure;
sintering the at least one first joint surface to the at least one second joint surface such that the first lipped edge overlapping the second lipped edge are combined and such that the first support structure is combined to the second support structure to form the unitary part comprising the first additively manufactured ceramic part and the second additively manufactured ceramic part;
and
separating the first support structure and the second support structure from the unitary part.

10 more elements

Dependencies are inferred from the claim text.

Facts

Application: 18/238,209Filed 25 Aug 2023
Granted: 7 Jan 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification20 codes

B28B 11/02
Apparatus or processes for treating or working the shaped or preshaped articles: for attaching appendages, e.g. handles, spouts
B28B 1/001
Producing shaped prefabricated articles from the material: rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating…
B28B 1/002
Producing shaped prefabricated articles from the material: assembled from preformed elements
B28B 3/00
Producing shaped articles from the material by using presses