US 2021/0276089 A1Published application

Method for manufacturing parts or devices and forming transition layers facilitating removal of parts and devices from build-plates

AssigneeWarsaw Orthopedic, Inc.

InventorsAdriaan J. Kuyler, Dawin A. Rodriguez Santiago, Keith Miller

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Abstract

A method for manufacturing parts or devices using additive manufacturing is provided. The method forms the parts or devices, and also forms a transition layer or transition layers of partially or incompletely sintered powder between a build-plate and/or supports provided on the build-plate, and/or a gap or gaps of unsintered powder, or partially or incompletely sintered powder between the supports and the parts. The transition layer(s) and the gap(s) facilitate separation of the parts or devices from the build-plate or the supports provided on the build-plate.

Claims20

Dependent claims

A method of forming a part or device, the method comprising:

providing a build-plate having an upper surface;
depositing a first set of one or more layers of powdered metal on the upper surface of the build-plate;
solidifying an upper portion of the first set of one or more layers of powdered metal to form a first solid layer, and forming a transition layer from a lower portion of the first layer of powdered metal by leaving the lower portion of the first set of one or more layers of powdered metal partially/incompletely solidified;
after formation of the first solid layer, depositing a second set of one or more layers of powdered metal on an upper surface of the first solid layer;
solidifying the second set of one or more layers of powdered metal to form a second solid layer attached to the first solid layer;
after formation of the second solid layer, depositing a third set of one or more layers of powdered metal on an upper surface of the second solid layer;
solidifying the third set of one or more layers of powdered metal to form a third solid layer attached to the second solid layer;
and
removing the part or device formed by the first solid layer, the second solid layer, and the third solid layer by separating the part or device from the build-plate at the transition layer,
wherein the transition layer eases separation of the part or device from the build-plate.

7 more elements

A method of forming a part or device, the method comprising:

providing a build-plate having a first upper surface;
depositing a first set of one or more layers of powdered metal on the first upper surface of the build-;
solidifying a first portion of the first set of one or more layers of powdered metal into a first solid layer formed as a vertical portion;
solidifying a second portion of the first set of one or more layers of powder metal into a support provided adjacent the vertical portion;
depositing a second set of one or more layers of powdered metal on the vertical portion and an upper surface of the support;
solidifying a first portion of the second set of one or more layers of powdered metal adjacent the vertical support to form a first portion of a second solid layer attached to the vertical portion, forming a transition layer from a second portion of the second set of one or more layers of powdered metal adjacent the support by leaving the second portion of the second set of one or more layers of powdered metal partially/incompletely solidified, and solidifying a third portion of the second set of one or more layers of powder metal adjacent the first portion of the second solid layer and adjacent the transition layer to form a second portion of the second solid layer attached to the first portion of the second solid layer and supported by the transition layer;
after formation of the second solid layer, depositing a third set of one or more layers of powdered metal on an upper surface of the second solid layer;
solidifying the third set of one or more layers of powdered metal to form a third solid layer attached to the second solid layer;
and
removing the part or device formed by the vertical portion, the first solid layer, the second solid layer, and the third solid layer by separating the part or device from the support at the transition layer,
wherein the transition layer eases separation of the part or device from the support.

8 more elements

A method of forming a part or device, the method comprising:

providing a build-plate having a first upper surface;
depositing a first set of one or more layers of powdered metal on the first upper surface of the build-plate;
solidifying a first portion of the first set of one or more layers of powdered metal into a first solid layer formed as a vertical portion;
solidifying a second portion of the first set of one or more layers of powdered metal into a support provided adjacent the vertical portion;
depositing a second set of one or more layers of powdered metal on the vertical portion and an upper surface of the support;
forming a transition layer from a first portion of the second set of one or more layers of powdered metal by leaving the first portion of the second set of one or more layers of powdered metal partially/incompletely solidified;
solidifying a second portion of the second set of one or more layers of powdered metal to form a first portion of a second solid layer above and attached to the first solid layer;
solidifying a third portion of the second set of one or more layers of powdered metal to form a second portion of the second solid layer above the transition layer, and adjacent and attached to the first portion of the second solid layer;
and
removing the part or device formed by the vertical portion, the first solid layer, and the second solid layer by separating the part or device from the support at the transition layer,
wherein the second solid layer of the second set of one or more layers of powdered metal is cantilevered over the support by the vertical portion, and the transition layer eases separation of the part or device from the support.

8 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/812,238Filed 6 Mar 2020
Published: 9 Sep 2021
Term ends: Not estimatedThe source records don’t support an estimate.

Classification12 codes

B22F 10/00
Additive manufacturing of workpieces or articles from metallic powder
B22F 10/40
Additive manufacturing of workpieces or articles from metallic powder: structures for supporting workpieces or articles during manufacture and…
B22F 5/003
Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product: articles made for being fractured or…
B22F 10/385
To achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures: overhang structures

Family

US 11,285,540 B2Related patent
US 2021/0276089 A1This patent

From the US filing history. Foreign family members aren’t listed.

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