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US 9,815,118 B1Granted
Fabricating multi-part assemblies
AssigneeDesktop Metal, Inc.
InventorsPeter Alfons Schmitt, Jonah 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
Techniques are disclosed for fabricating multi-part assemblies. In particular, by forming release layers between features such as bearings or gear teeth, complex mechanical assemblies can be fabricated in a single additive manufacturing process.
Claims29
A method comprising:
- fabricating a first object from a first material, wherein the first material includes a powdered material and a binder system, the binder system including one or more binders that resist deformation of a net shape of the first object during processing of the first object into a final part;
- applying an interface layer adjacent to a first surface of the first object;
- and
- fabricating a second surface of a second object from a second material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object, wherein the interface layer resists bonding of the first surface to the second surface during sintering, and wherein the interface layer reduces to a powder during sintering of the first material.
1 more element
A method comprising:
- receiving an article including a first object from a first material, wherein the first material includes a powdered material and a binder system, the binder system including one or more binders that resist deformation of a net shape of the first material during processing of the first material into a final part, the article further including an interface layer adjacent to a first surface of the first object, and the article further including a second surface of a second object from a second material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object, and wherein the interface layer resists bonding of the first surface to the second surface during sintering;
- and
- processing the article to form the object into a final part based on the first object and the second object, wherein processing includes at least one of debinding the article and sintering the article, and wherein the interface layer reduces to a powder during sintering of the first material.
A method comprising:
- fabricating a first object from a first material, wherein the first material includes a powdered material and a binder system, the binder system including one or more binders that resist deformation of a net shape of the first object during processing of the first object into a final part;
- applying an interface layer adjacent to a first surface of the first object;
- fabricating a second surface of a second object from a second material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object, wherein the first object and the second object form a multi-part mechanical assembly including one or more moving parts within a casing, and wherein the interface layer resists bonding of the first surface to the second surface during sintering;
- and
- providing a physical exit path from the casing for a third material of the interface layer.
2 more elements
A method comprising:
- fabricating a first object from a first material, wherein the first material includes a powdered material and a binder system, the binder system including one or more binders that resist deformation of a net shape of the first object during processing of the first object into a final part;
- applying an interface layer adjacent to a first surface of the first object;
- fabricating a second surface of a second object from a second material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object, wherein the first object and the second object form a multi-part mechanical assembly, and wherein the interface layer resists bonding of the first surface to the second surface during sintering;
- and
- providing a physical exit path within the multi-part mechanical assembly for extraction of a support material, wherein the support material reduces to a powder during sintering of the first material.
2 more elements
A method comprising:
- fabricating a first object from a first material, wherein the first material includes a powdered material and a binder system, the binder system including one or more binders that resist deformation of a net shape of the first object during processing of the first object into a final part;
- applying an interface layer adjacent to a first surface of the first object, the interface layer formed by at least one of inkjetting, micropipetting, and painting an interface material onto the first surface to form the interface layer, the interface material including a ceramic-loaded polymer;
- and
- fabricating a second surface of a second object from a second material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object, and wherein the interface layer resists bonding of the first surface to the second surface during sintering.
1 more element
A method comprising:
- fabricating a first object from a first material, wherein the first material includes a powdered material and a binder system, the binder system including one or more binders that resist deformation of a net shape of the first object during processing of the first object into a final part;
- applying an interface layer adjacent to a first surface of the first object, the interface layer formed by at least one of inkjetting, micropipetting, and painting an interface material onto the first surface to form the interface layer, the interface material including a ceramic-loaded suspension or a ceramic-loaded slurry;
- and
- fabricating a second surface of a second object from a second material at a location adjacent to the interface layer and opposing the first surface of the first object, wherein the second object is structurally independent from and mechanically related to the first object, and wherein the interface layer resists bonding of the first surface to the second surface during sintering.
1 more element
Dependencies are inferred from the claim text.