Interface layers for removable supports
AssigneeDesktop Metal, Inc.
InventorsJonah Samuel Myerberg, Ricardo Fulop, Michael Andrew Gibson, Matthew David Verminski, Richard Remo Fontana, Christopher Allan Schuh, Yet-Ming Chiang, Anastasios John Hart
Life of this patent
Estimating the term…
Abstract
Support structures are used in certain additive fabrication processes to permit fabrication of a greater range of object geometries. For additive fabrication processes with materials that are subsequently sintered into a final part, an interface layer is formed between the object and support in order to inhibit bonding between adjacent surfaces of the support structure and the object during sintering.
Claims20
A method of fabricating a metallic three-dimensional object having a separable support, comprising the steps of:
- forming a plurality of successive layers of build material into a desired shape of the three-dimensional object and a support structure, the build material including a binder system and a metal powder;
- wherein during the step of forming a plurality of successive layers, forming an interface of non-sinterable material between the desired shape of the three-dimensional object and the support structure;
- debinding at least a portion of the binder system;
- and
- sintering the shape of the three-dimensional object into a densified final object and the support structure into a densified support structure separable at the interface of non-sinterable material.
A method of fabricating a three-dimensional object having a separable support, comprising the steps of:
- forming a plurality of successive layers of build material into a desired shape of the three-dimensional object and a support structure, the build material including a binder system and a sinterable powder;
- wherein during the step of forming a plurality of successive layers, forming an interface of non-sinterable material between the desired shape of the three-dimensional object and the support structure;
- debinding at least a portion of the binder system;
- and
- sintering the shape of the three-dimensional object into a densified final object and the support structure into a densified support structure separable at the interface of non-sinterable material.
A method of fabricating a metallic three-dimensional object, comprising the steps of:
- depositing a build material into a desired shape of the three-dimensional object and a support structure, the build material including a binder system and a sinterable powder;
- wherein the support structure at least partially underlies the three-dimensional object and provides structural support to at least a portion of a feature thereof against gravity-induced deformation;
- wherein during the step of depositing the build material, depositing a non-sinterable material between the desired shape of the three-dimensional object and the support structure;
- debinding at least a portion of the binder system;
- sintering the shape of the three-dimensional object into a densified final object and the support structure into a densified support structure;
- and
- applying a mechanical force sufficient to separate the densified final object and the support structure at the non-sinterable material without damage to the densified final object.
Dependencies are inferred from the claim text.