SEDIMENT CONTROLLING IN PNEUMATIC JETTING OF METAL FOR ADDITIVE MANUFACTURING

• US 20170252810A1
• Filed: 03/03/2017
• Published: 09/07/2017
• Est. Priority Date: 03/03/2016
• Status: Abandoned Application

• Current Assignee: Desktop Metal, Inc.
• Original Assignee: Desktop Metal, Inc.
• Inventors: Myerberg, Jonah Samuel, Natchurivalapil Rappai James, Toshana Krishna, Sachs, Emanuel Michael, Hoisington, Paul A., Li, Kevin Michael
• Application Number:
  US15/449,596
• Publication Number:
  US 20170252810A1
• Time in Patent Office: Days
• CPC Class Codes: B22F 10/22 Direct deposition of molten metal
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 12/10 Auxiliary heating means
• CPC Class Codes: B22F 12/22 Driving means
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 2009/0892 casting nozzle; controlling metal stream in or after the casting nozzle
• CPC Class Codes: B22F 2202/05 Use of magnetic field
• CPC Class Codes: B22F 2203/13 pressure
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/003 Apparatus, e.g. furnaces in general F27B
• CPC Class Codes: B22F 3/115 by spraying molten metal, i.e. spray sintering, spray casting
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Devices, systems, and methods are directed to separating sediment from liquid metal ejected, through pneumatic force, from a nozzle moving along a controlled three-dimensional pattern to fabricate a three-dimensional object. The separation of the sediment from the liquid metal can reduce the likelihood that the nozzle will become clogged or otherwise degraded during fabrication of the three-dimensional object or over the course of fabrication of multiple objects. Accordingly, the separation of the sediment from the liquid metal can facilitate, for example, the use of pneumatic ejection of liquid metal for high volume production of parts.

Claims

1. An additive manufacturing system, the system comprising:

a nozzle defining a volume, a first port, a second port, and a discharge orifice in fluid communication with one another;

a source of a pressurized gas in selective fluid communication with the volume of the nozzle through the first port;

a media supply in fluid communication with the volume of the nozzle through the second port; and

one or more baffles disposed in the volume of the nozzle such that an axis defined by the discharge orifice and the second port intersects the one or more baffles, the one or more baffles oriented to direct sediment of a liquid form of a metal in the volume to a reservoir portion of the volume, the reservoir portion away from the discharge orifice.

2. The system of claim 1, wherein the one or more baffles define a non-linear path between the discharge orifice and the reservoir portion of the volume.

3. The system of claim 2, wherein the non-linear path between the discharge orifice and the reservoir portion of the volume includes an increase in height, along an axis perpendicular to the discharge orifice, along the non-linear path from the reservoir portion to the discharge orifice.

4. The system of claim 1, wherein the one or more baffles span a dimension of the volume.

5. The system of claim 1, wherein the one or more baffles include a plurality of baffles substantially parallel to one another.

6. The system of claim 1, wherein the one or more baffles are angled with respect to an axis perpendicular to the discharge orifice.

7. The system of claim 1, wherein the media supply is configured to move a solid form of metal into the volume through the second port.

8. The system of claim 7, wherein the second port is vented to atmosphere such that pressurized gas exits the volume through the second port.

9. The system of claim 1, wherein a flow of pressurized gas through the first port is substantially unimpeded by the one or more baffles.

10. The system of claim 1, further comprising a heater arranged to heat at least portions of the nozzle defining the discharge orifice and along which the one or more baffles are disposed.

11. The system of claim 10, wherein the heater includes one or more of a resistance heater, an induction heater, a convection heater, and a radiation heater.

12. A method of additive manufacturing, the method comprising:

directing a metal into a volume defined by a nozzle;

moving a discharge orifice and a build plate relative to one another along a controlled three-dimensional pattern, the discharge orifice defined by the nozzle and in fluid communication with the volume;

separating, in the volume, a liquid form of the metal from a sediment; and

based at least in part on a position of the discharge orifice along the controlled three-dimensional pattern, delivering pressurized gas into the volume to eject the liquid form of the metal from the discharge orifice to form a three-dimensional object on the build plate.

13. The method of claim 12, wherein separating the liquid form of the metal from the sediment includes moving the liquid form of the metal along a non-linear path from a sediment reservoir in the volume to the discharge orifice.

14. The method of claim 13, wherein separating the liquid form of the metal from the sediment further includes increasing, in the volume, a height of the liquid form of the metal relative to the discharge orifice.

15. The method of claim 13, wherein the non-linear path is at least partially defined by one or more baffles disposed in the volume.

16. The method of claim 12, wherein the liquid form of the metal is separated from the sediment as the pressurized gas is delivered into the volume.