SYSTEM AND METHOD FOR BUILDING THREE-DIMENSIONAL OBJECTS WITH METAL-BASED ALLOYS
First Claim
1. A digital manufacturing system for building a three-dimensional object with a metal-based alloy, the system comprising:
- a build chamber configured to be maintained at one or more temperatures of at least about 200°
C.;
a build platform disposed within the build chamber;
at least one extrusion line configured to heat the metal-based alloy up to a temperature between a solidus temperature of the metal-based alloy and a liquidus temperature of the metal-based alloy;
a deposition head disposed within the build chamber, and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern;
an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head; and
at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, wherein the at least one gantry assembly comprises a motor disposed outside of the build chamber.
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Accused Products
Abstract
A digital manufacturing system comprises a build chamber, a build platform disposed within the build chamber, at least one extrusion line configured to heat a metal-based alloy up to a temperature between solidus and liquidus temperatures of the metal-based alloy, a deposition head disposed within the build chamber and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern, an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head, and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, where the at least one gantry assembly comprises a motor disposed outside of the build chamber.
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Citations
20 Claims
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1. A digital manufacturing system for building a three-dimensional object with a metal-based alloy, the system comprising:
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a build chamber configured to be maintained at one or more temperatures of at least about 200°
C.;a build platform disposed within the build chamber; at least one extrusion line configured to heat the metal-based alloy up to a temperature between a solidus temperature of the metal-based alloy and a liquidus temperature of the metal-based alloy; a deposition head disposed within the build chamber, and configured to deposit the heated metal-based alloy onto the build platform in a predetermined pattern; an umbilical having a first end located outside of the build chamber and a second end connected to the deposition head; and at least one gantry assembly configured to cause relative motion between the build platform and the deposition head within the build chamber, wherein the at least one gantry assembly comprises a motor disposed outside of the build chamber. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method for building a three-dimensional object in a layer-by-layer manner with a digital manufacturing system, the method comprising:
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heating a build chamber of the digital manufacturing system to one or more temperatures of at least about 200°
C.;heating a metal-based alloy in an extrusion line of the digital manufacturing system, wherein the metal-based alloy is heated up to a temperature between a solidus temperature of the metal-based alloy and a liquidus temperature of the metal-based alloy; depositing the heated metal-based alloy from a deposition head of the digital manufacturing system onto a build platform of the digital manufacturing system in a predetermined pattern; and solidifying the heated metal-based alloy to provide a re-solidified alloy that is substantially free of dendrites. - View Dependent Claims (11, 12, 13, 14)
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15. A method for building a three-dimensional object in a layer-by-layer manner with a digital manufacturing system, the method comprising:
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substantially removing oxygen-containing gases from a build chamber of the digital manufacturing system; heating the build chamber to one or more temperatures of at least about 200°
C.;providing an alloy that comprises aluminum and silicon, the aluminum constituting about 90% by weight to about 95% by weight of the alloy, and the silicon constituting about 5% by weight to about 10% by weight of the alloy; heating the alloy to a temperature that is above a solidus temperature of the alloy and that is below a liquidus temperature of the alloy; depositing the heated alloy onto a build platform of the digital manufacturing system in a predetermined pattern; and solidifying the deposited alloy. - View Dependent Claims (16, 17, 18, 19, 20)
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Specification