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WO2025145060A1 - Dispositifs et procédés pour faciliter la fabrication additive multi-chimies - Google Patents

Dispositifs et procédés pour faciliter la fabrication additive multi-chimies Download PDF

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Publication number
WO2025145060A1
WO2025145060A1 PCT/US2024/062124 US2024062124W WO2025145060A1 WO 2025145060 A1 WO2025145060 A1 WO 2025145060A1 US 2024062124 W US2024062124 W US 2024062124W WO 2025145060 A1 WO2025145060 A1 WO 2025145060A1
Authority
WO
WIPO (PCT)
Prior art keywords
print head
build platform
liquid formulation
printing system
fluid supply
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/062124
Other languages
English (en)
Inventor
William BUCKLEY JR.
William SHAMBLEY
Austin W. BRITTAIN
Mike Bell
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Beehive Industries LLC
Original Assignee
Beehive Industries LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Beehive Industries LLC filed Critical Beehive Industries LLC
Publication of WO2025145060A1 publication Critical patent/WO2025145060A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/14—Formation of a green body by jetting of binder onto a bed of metal powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/58—Means for feeding of material, e.g. heads for changing the material composition, e.g. by mixing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/112—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using individual droplets, e.g. from jetting heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—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
    • B29C64/40—Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
    • B22F12/50—Means for feeding of material, e.g. heads
    • B22F12/55—Two or more means for feeding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials

Definitions

  • TECHNICAL FIELD [0002] The technology discussed below relates generally to three-dimensional printing, and more specifically to methods and devices for facilitating multi-chemistry additive manufacturing in three-dimensional printing.
  • BACKGROUND [0003] Three-dimensional (3D) printing, which may also be referred to as additive manufacturing, has become common in modern manufacturing processes.
  • 3D printer is a 3D binder jet printer that can be used for making ceramic, metal, or sand-based parts.
  • Typical 3D binder jet printers employ layering techniques to form successive thin cross-sections of a desired article. The individual cross-sections are formed by bonding together adjacent grains of a granular material on a generally planar surface of a bed of the granular material.
  • Each layer is bonded to a previously formed layer to form the desired 3D article at the same time as the grains of each layer are bonded together.
  • Such 3D printers can create parts directly from computer- generated design data and can produce parts having complex geometries. Moreover, 3D printing can be quicker and less expensive than machining of prototype parts or production of cast or molded parts by conventional "hard” or “soft” tooling techniques, that can take from a few weeks to several months, depending on the complexity of the desired article. [0004] Improvements to one or more aspects of such 3D binder jet printers may be beneficial.
  • such methods may include providing a first liquid formulation to a print head of a 3D printing system.
  • a second liquid formulation may also be provided to the print head of the 3D printing system.
  • the print head may be controlled to move across a build platform while selectively disposing the first liquid formulation and the second liquid formulation in a single pass to form layers of a 3D object.
  • FIG. 2 is a conceptual figure of at least one example of a 3D article formed utilizing a 3D printing system of the present disclosure.
  • FIG. 3 is a conceptual figure of at least one example of a 3D article formed utilizing a 3D printing system of the present disclosure.
  • FIG. 4 is a flow diagram illustrating at least one example of a method of making a 3D printing system.
  • FIG. 5 is a flow diagram illustrating at least one example of a method of additive manufacturing. DETAILED DESCRIPTION [0016]
  • the description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts and features described herein may be practiced.
  • FIG. 1 is a block diagram illustrating an example of a 3D printing system 100. Generally speaking, the 3D printing system 100 shown in FIG.
  • the 3D printing system 100 generally includes a build platform 104 and a print head 106.
  • the print head 106 can be movable across the build platform 104 and/or can be stationary.
  • the print head 106 includes one or more orifices through which a liquid formulation can be delivered from the print head 106 to each layer of the article 102 along the build platform 104.
  • the print head 106 may be arranged to expel a plurality of different liquid formulations from the one or more orifices of the print head 106.
  • a first liquid formulation supply 105 and a second liquid formulation supply 107 may each be coupled with the print head 106 to provide a respective liquid formulation to the print head 106.
  • liquid formulations may include binder compositions, ceramic materials, and/or other refractory materials.
  • binder compositions may include waxes, resins, solvents, and/or carrier fluids loaded with particles of one or more materials.
  • a liquid formulation in the form of a ceramic material may include ceramic particles loaded in a curable binder.
  • the print head 106 may include many heads in line that scan back and forth over the area of the build platform 104, or the print head 106 may be a series of print bars to enable single pass production.
  • the carrier fluids for a slurry and binder may be solvents, reactive resins, waxes, or some combination thereof.
  • the print head 106 may be controlled to deliver the two or more liquid formulations to the build platform 104 in predetermined two-dimensional patterns, with each pattern corresponding to a respective layer of the three-dimensional article 102.
  • two or more supplies of different liquid formulations may be coupled with the print head 106 such that each respective liquid formulation may be provided to the print head 106 simultaneously.
  • one or more orifices may be employed to deposit a first liquid formulation, while one or more different orifices may be employed to deposit a second different liquid formulation for a two-dimensional pattern for a single layer.
  • one or more orifices may be configured to selectively deposit each of the different liquid formulations by selectively depositing a first liquid formulation for a portion of a two- dimensional pattern for a respective layer and a second liquid formulation for another portion of the two-dimensional pattern for the same respective layer.
  • the delivery of the respective liquid formulations associated with each layer may be a printing operation in which the various liquid formulation materials in each respective layer of the three-dimensional composition is selectively joined along the predetermined two-dimensional layers.
  • the multiple liquid formulations can be applied to each layer Attorney Docket No. BEEHI-1005PCT Provisional Patent Application at the same time, or during a single pass of the print head 106.
  • some embodiments may be configured to apply the multiple liquid formulations to each layer in more than one pass of the print head 106 for each layer, such as if the print head 106 uses the same orifice to apply two different liquid formulations.
  • the 3D printing system 100 may be configured to deposit liquid formulations directly onto the build platform 104 without the use of a powder bed. In other implementation, the 3D printing system 100 may be configured to utilize a build platform 104 implemented as a powder bed to deposit liquid formulations on layers of granular material.
  • a liquid formulation including a binder composition such as liquid wax or other investment materials may be provided by a wax (or resin) fluid supply to one or more orifices of the print head 106.
  • a different liquid formulation comprised of ceramic or other refractory materials may be provided by a ceramic fluid supply to one or more orifices of the print head 106.
  • the print head 106 may be equipped with inkjet nozzles for depositing both the binder composition and the ceramic material.
  • the different liquid formulations may be simultaneously deposited by the print head 106 according to the predetermined two-dimensional patterns for each respective layer of the three-dimensional article 102, or the different liquid formulations may be deposited at different times by the print head 106 for each respective layer of the three-dimensional article 102.
  • the 3D printing system 100 may be configured to form the article 102 from a granular material 108.
  • the article 102 may be a three-dimensional composition, formed with a plurality of binder compositions and a granular material.
  • the 3D printing system 100 utilizing a granular material 108 may include a powder deposition mechanism 109.
  • the powder deposition mechanism 109 may include a spreader 110 and a supply 112 of granular material, with the build platform 104 configured as a powder bed.
  • the powder deposition mechanism 109 may be operated to deposit a layer of granular material by depositing granular material 108 onto the build platform 104.
  • the spreader 110 may be movable to deposit the layer of granular material onto the build platform 104. In some embodiments, the spreader 110 may move independent of the print head Attorney Docket No.
  • the print head 106 may be controlled to deliver liquid such as two or more liquid formulations (e.g., two or more binder compositions), to the powder bed in predetermined two- dimensional patterns, with each pattern corresponding to a respective layer of the three- dimensional article 102.
  • liquid formulations e.g., two or more binder compositions
  • the delivery of the respective liquid formulations (e.g., binder compositions) associated with each layer may be a printing operation in which the various materials in each respective layer of the three-dimensional composition is selectively joined along the predetermined two-dimensional layers.
  • the 3D printing system 100 may further include a controller 118 in electrical communication with one or more other system components.
  • the controller 118 may be in electrical communication with the print head 106, the build platform 104, supplies of various liquid formulations, the supply 112 of granular material, and/or the spreader 110, according to the various embodiments.
  • a non-transitory, computer-readable storage medium 120 may be in communication with the controller 118 and have stored thereon a three-dimensional model 122 and instructions for carrying out any one or more of the methods described herein.
  • the non-transitory, computer-readable storage medium 120 may comprise previously prepared instructions.
  • Such instructions when executed by the controller 118, may operate one or more components of the 3D printing system 100 to fabricate one or more three-dimensional compositions.
  • one or more processors of the controller 118 can execute instructions to move the print head 106 across the surface of the build platform 104 and deposit a liquid formulation (e.g., binder composition, ceramic material) at specific locations.
  • a liquid formulation e.g., binder composition, ceramic material
  • the 3D printing system 100 may operate with or without an energy such as IR laser or IR to heat and destabilize the slurry layers. Destabilizing the metal facing surfaces and building up the density by printing additional Attorney Docket No. BEEHI-1005PCT Provisional Patent Application fine particles may help with castability and surface finish without increasing the total bulk of the part.
  • the illustrative 3D printing systems 100 are provided as some examples of a suitable 3D printing systems 100 and are not intended to be limiting with respect to the techniques described herein.
  • the media bed can be a dry particulate, a slurry of particles in a solvent, a slurry on a reel to reel tape casting system, or the art could be practiced without a media bed at all (i.e. modifying the composition of a material jetting 3D printing process).
  • the 3D printing system 100 may be employed in an additive manufacturing process, such as investment casting. Investment casting is a metal manufacturing method used to make a broad spectrum of metal parts for industrial uses, ranging from jewelry and dental applications to turbine blades and other parts.
  • the process steps in traditional investment casting include utilizing a pattern, typically made of wax, that is dipped into a ceramic slurry to build a refractory shell. The shell is then fired at high temperatures to remove the pattern, creating a negative mold which is an exact duplicate of the pattern. Once any residue, such as ash, is cleaned out of the ceramic shell, molten metal is poured into the mold. Upon freezing of the metal, the ceramic mold is removed to reveal the casting. [0033] For castings with more complicated internal geometry, such as an internally cooled jet engine turbine blade, the negative space on the inside of a wax pattern cannot be reliably filled with ceramic slurry during a conventional low-pressure dipping process, so a ceramic core may be conventionally manufactured in advance, typically in an injection molding tool.
  • 3D printed patterns can be shelled and burned out in the traditional refractory process with slight procedural modifications.
  • Traditional investment casting shells are produced by dipping the pattern in a series of ceramic slurries, with a drying step between each dip in the process. The initial layer is made using a very fine, low viscosity slurry, with particles typically less than 325 mesh.
  • This face coat determines the surface quality of the metal casting.
  • various mixes of alumina, silica, zircon, or other refractory materials may be used.
  • other additives maybe be used in the face coat.
  • the 3D printing system 100 is configured to utilize two or more liquid formulations (e.g., binder compositions, ceramic materials) delivered by the print head 106 to the build platform 104.
  • a liquid formulation in the form of a binder composition may include a space-filling sacrificial resin or wax.
  • Such an example of a binder composition may be employed to create internal supports or to modify porosity of the final part, such as by dendritic connected porosity instead of randomly connected porosity.
  • FIG. 3 illustrates an example of another 3D article 300 formed utilizing a 3D printing system 100 of the present disclosure.
  • the 3D article 300 may be formed utilizing a 3D printing system 100 configured with the use of a granular material or powder bed.
  • the article 300 may include a shell 302 and a core 304 formed by the 3D printing system 100.
  • the shell 302 and/or the core 304 may be formed to include at least two different binder compositions.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Producing Shaped Articles From Materials (AREA)

Abstract

Des systèmes d'impression en trois dimensions (3D) peuvent comprendre une plateforme de construction et une tête d'impression adjacente à la plateforme de construction. La tête d'impression peut être configurée pour déposer une pluralité de formulations liquides différentes sur la plateforme de construction. Des procédés de fabrication de systèmes d'impression 3D peuvent comprendre le positionnement d'une tête d'impression adjacente à une plateforme de construction, avec une première alimentation en fluide et une seconde alimentation en fluide couplée à la tête d'impression, facilitant le dépôt d'une pluralité de différentes formulations liquides à partir de la tête d'impression sur la plateforme de construction. Des procédés de fabrication additive peuvent comprendre la fourniture d'une première formulation liquide et d'une seconde formulation liquide à une tête d'impression d'un système d'impression 3D, et la disposition sélective de la première formulation liquide et de la seconde formulation liquide en une seule passe pour former des couches d'un objet 3D. L'invention concerne également d'autres aspects, modes de réalisation et caractéristiques.
PCT/US2024/062124 2023-12-28 2024-12-27 Dispositifs et procédés pour faciliter la fabrication additive multi-chimies Pending WO2025145060A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202363615686P 2023-12-28 2023-12-28
US202363615495P 2023-12-28 2023-12-28
US63/615,495 2023-12-28
US63/615,686 2023-12-28

Publications (1)

Publication Number Publication Date
WO2025145060A1 true WO2025145060A1 (fr) 2025-07-03

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Application Number Title Priority Date Filing Date
PCT/US2024/062124 Pending WO2025145060A1 (fr) 2023-12-28 2024-12-27 Dispositifs et procédés pour faciliter la fabrication additive multi-chimies

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050059757A1 (en) * 2003-08-29 2005-03-17 Z Corporation Absorbent fillers for three-dimensional printing
US20160158962A1 (en) * 2014-12-08 2016-06-09 Tethon Corporation Three-dimensional (3d) printing
US20230173756A1 (en) * 2017-02-24 2023-06-08 Hewlett-Packard Development Company, L.P. Three-dimensional printing

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050059757A1 (en) * 2003-08-29 2005-03-17 Z Corporation Absorbent fillers for three-dimensional printing
US20160158962A1 (en) * 2014-12-08 2016-06-09 Tethon Corporation Three-dimensional (3d) printing
US20230173756A1 (en) * 2017-02-24 2023-06-08 Hewlett-Packard Development Company, L.P. Three-dimensional printing

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