# US 2021/0276089 A1 · Method for manufacturing parts or devices and forming transition layers facilitating removal of parts and devices from build-plates > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0276089 A1 - Document ID: US20210276089A1 - Status: Published application - Kind: A1 - Application number: 16/812,238 - Filed: 2020-03-06 - Published: 2021-09-09 - Earliest claimed: 2020-03-06 - Assignees: Warsaw Orthopedic, Inc. - Applicants: Warsaw Orthopedic, Inc. - Inventors: Adriaan J. Kuyler; Dawin A. Rodriguez Santiago; Keith Miller - Web page: https://patentgrep.com/patent/US20210276089A1 ## CPC - B22F 10/00: Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00) - B22F 10/40: Structures for supporting workpieces or articles during manufacture and removed afterwards - B22F 5/003: {Articles made for being fractured or separated into parts} - B22F 10/385: {Overhang structures} - B22F 10/10: Formation of a green body - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - B33Y 10/00: Processes of additive manufacturing - 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 - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) The method of claim 1, wherein the solidifying is performed via laser sintering of the upper portion of the first set of one or more layers of powder, the second set of one or more layers of powdered metal, and the third set of one or more layers of powdered metal. ### Claim 3 (depends on 2) The method of claim 2, wherein, during formation of the first solid layer, a laser performing the laser sintering does not penetrate into the lower portion of the first set of one or more layers of powdered metal. ### Claim 4 (depends on 1) The method of claim 1, wherein a lower surface of the first solid layer is relatively smooth after separation from the build-plate at the transition layer. ### Claim 5 (depends on 1) The method of claim 1, wherein the first set of one or more layers of powdered metal, the second set of one or more layers of powder, and the third set of one or more layers of powdered metal each have substantially uniform depths. ### Claim 6 (depends on 5) The method of claim 5, wherein the substantially uniform depths of the first set of one or more layers of powdered metal, the second set of one or more layers of powdered metal, and the third set of one or more layers of powdered metal are different. ### Claim 7 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. ### Claim 8 (depends on 7) The method of claim 7, wherein at least a portion of the second solid layer is cantilevered over the support via attachment to the vertical portion. ### Claim 9 (depends on 7) The method of claim 7, wherein the vertical portion is a first vertical portion, and further comprising solidifying a third portion of the first set of one or more layers of powdered metal into a second vertical portion, the first vertical portion being formed on one side of the support, and the second vertical portion being formed on the other side of the support. ### Claim 10 (depends on 9) The method of claim 9, wherein at least a portion of the second solid layer is bridged over the support via attachment to the first vertical portion and the second vertical portion. ### Claim 11 (depends on 7) The method of claim 7, wherein the solidifying is performed via laser sintering of the first portion and the second portion of the first set of one or more layers of powdered metal, the first portion and the third portion of the second set of one or more layers of powdered metal, and the third set of one or more layers of powdered metal. ### Claim 12 (depends on 11) The method of claim 11, wherein, during formation of the second portion of the second set of one or more layers of powdered metal, a laser performing the laser sintering does not penetrate completely into the second portion of the second set of one or more layers of powdered metal. ### Claim 13 (depends on 7) The method of claim 7, wherein a lower surface of the third portion of the second solid layer is relatively smooth after separation from the support at the transition layer. ### Claim 14 (depends on 7) The method of claim 7, wherein the first set of one or more layers of powdered metal and the second set of one or more layers of powdered metal each have substantially uniform depths. ### Claim 15 (depends on 14) The method of claim 14, wherein the substantially uniform depths of the first set of one or more layers of powdered metal and the second set of one or more layers of powdered metal are different. ### Claim 16 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. ### Claim 17 (depends on 16) The method of claim 16, wherein the solidifying is performed via laser sintering of the first portion and the second portion of the first set of one or more layers of powdered metal, the second portion and the third portion of the second set of one or more layers of powdered metal. ### Claim 18 (depends on 17) The method of claim 17, wherein, during formation of the first portion of the second set of one or more layers of powdered metal, a laser performing the laser sintering does not penetrate completely into the first portion of second set of one or more layers of powdered metal. ### Claim 19 (depends on 16) The method of claim 16, wherein the first set of one or more layers of powdered metal and the second set of one or more layers of powdered metal each have substantially uniform depths. ### Claim 20 (depends on 19) The method of claim 19, wherein the substantially uniform depths of the first set of one or more layers of powdered metal and the second set of one or more layers of powdered metal are different.