Method and apparatus for fabrication of three-dimensional articles by thermal spray deposition
First Claim
1. A method for the fabrication of a three dimensional article comprising the steps ofa) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article;
- b) creating a second set of masks, each mask corresponding to at least one mask from the first set of masks and defining a complement to the cross section defined by a corresponding mask from the first set of masks;
c) alternatively placing on a work surface at least one mask from the first set and then at least one mask from the second set in accordance with a predetermined sequence;
d) spraying deposition material over each mask from the first set of masks and one of the work surface and deposition material on the work surface;
e) removing the mask after spraying the deposition material;
f) spraying a complementary material over each mask from the second set of masks and one of the work surface and complementary material on the work surface;
g) removing the mask after spraying the complementary material; and
h) removing the complementary material from the sprayed deposition material.
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Accused Products
Abstract
A method and apparatus for forming a three-dimensional object by thermal spraying utilizes a plurality of masks positioned and removed over a work surface in accordance with a predetermined sequence. The masks correspond to cross sections normal to a centerline through the workpiece. One set of masks defines all cross sections through the workpiece. A second set of masks contains at least one masks which corresponds to each mask of the first set. Masks from each set are alternatively placed above a work surface and sprayed with either a deposition material from which the workpiece will be made or a complementary material. In this manner, layers of material form a block of deposition material and complementary material. Then, the complementary material which serves as a support structure during forming is removed. Preferably, the complementary material has a lower melting temperature than the deposition material and is removed by heating the block. Alternatively, one could mask only for the deposition material and remove complementary material overlying the deposition material after each spraying of complementary material.
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Citations
37 Claims
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1. A method for the fabrication of a three dimensional article comprising the steps of
a) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article; -
b) creating a second set of masks, each mask corresponding to at least one mask from the first set of masks and defining a complement to the cross section defined by a corresponding mask from the first set of masks; c) alternatively placing on a work surface at least one mask from the first set and then at least one mask from the second set in accordance with a predetermined sequence; d) spraying deposition material over each mask from the first set of masks and one of the work surface and deposition material on the work surface; e) removing the mask after spraying the deposition material; f) spraying a complementary material over each mask from the second set of masks and one of the work surface and complementary material on the work surface; g) removing the mask after spraying the complementary material; and h) removing the complementary material from the sprayed deposition material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A method for fabrication of a three-dimensional article comprising the steps of:
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a) creating a first set of masks, each mask corresponding to at least a portion of a cross section through the article such that there is at least one mask in the first set for every parallel cross section through the article normal to a centerline through the article; b) placing at least one mask over a work surface; c) spraying a deposition material over the work surface and mask placed thereover; d) removing the at least one mask; e) spraying a complementary material over the work surface and deposition material sprayed thereon to form a layer of deposition material and complementary material; f) machining the layer to a selected thickness thereby removing all complementary material from an exposed top surface of the deposition material; g) repeating steps b thru f as necessary to build up the article; and h) removing the complementary material from the deposition material. - View Dependent Claims (19, 20, 21, 22, 23)
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24. An apparatus for forming an integral three-dimensional article by thermally spraying layers of material comprising:
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a) a work surface; b) means for supplying to the work surface masks corresponding to cross sections through the article; c) means for placing the masks over the work surface and removing them therefrom in accordance with a predetermined sequence; d) means for thermally spraying a deposition material over the masks, the work surface, and material deposited on a work surface, and e) means for thermally spraying a complementary material over the masks, the work surface and material deposited on the mask surface. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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Specification