Methods of securing an initial layer during additive manufacturing of thermoplastic material
First Claim
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1. An additive manufacturing method, the method comprising:
- positioning a removable surface on a worktable;
applying an adhesive material to the removable surface;
depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed forming an uneven surface that protrudes from a surface of the adhesive material;
depositing a first plurality of layers of a first flowable material on the uneven surface of at least some of the plurality of pellets, wherein the first flowable material is heated prior to depositing the first flowable material on the plurality of pellets such that depositing the first flowable material on the plurality of pellets causes at least one pellet of the plurality of pellets to at least partially melt;
depositing a second plurality of layers of a second flowable material on the first plurality of layers; and
separating the second plurality of layers from the first plurality of layers.
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Abstract
In one embodiment, an additive manufacturing method including the steps of positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed; depositing a first plurality of layers of a flowable material on at least some of the plurality of pellets; and depositing a second plurality of layers of the flowable material on the first plurality of layers.
23 Citations
16 Claims
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1. An additive manufacturing method, the method comprising:
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positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed forming an uneven surface that protrudes from a surface of the adhesive material; depositing a first plurality of layers of a first flowable material on the uneven surface of at least some of the plurality of pellets, wherein the first flowable material is heated prior to depositing the first flowable material on the plurality of pellets such that depositing the first flowable material on the plurality of pellets causes at least one pellet of the plurality of pellets to at least partially melt; depositing a second plurality of layers of a second flowable material on the first plurality of layers; and separating the second plurality of layers from the first plurality of layers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 15)
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12. An additive manufacturing method, the method comprising:
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positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed forming an uneven surface that protrudes from a surface of the adhesive material; depositing a first plurality of layers of a flowable material on the uneven surface of at least some of the plurality of pellets, wherein the flowable material of the first plurality of layers is a thermoplastic material and each pellet of the plurality of pellets includes a same thermoplastic material as the thermoplastic material of the first plurality of layers; depositing a second plurality of layers of the flowable material on the first plurality of layers; and separating the first plurality of layers from the removable surface along an interface between the adhesive material and the plurality of pellets. - View Dependent Claims (13, 16)
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14. An additive manufacturing method, the method comprising:
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positioning a removable surface on a worktable; applying an adhesive material to the removable surface; depositing a plurality of pellets into the adhesive material, wherein at least a portion of each pellet of the plurality of pellets remains exposed forming an uneven surface that protrudes from a surface of the adhesive material; depositing a first plurality of layers of a first flowable material on the uneven surface of at least some of the plurality of pellets so as to cause at least one pellet of the plurality of pellets to at least partially melt; and depositing a second plurality of layers of a second flowable material on the first plurality of layers, wherein the first flowable material is different from the second flowable material.
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Specification