Three-dimensional printing techniques
First Claim
Patent Images
1. A process for making a component comprising the steps of(1) depositing a preselected quantity of a powder material;
- (2) spreading said powder material in a layer of preselected thickness over a predetermined confined region;
(3) applying a further material to selected regions of said layer of powder material which will cause said layer of powder material to become bonded at said selected regions;
(4) repeating steps (1), (2) and (3) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other;
(5) removing unbonded powder material which is not at said one or more selected regions to provide the component.
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Accused Products
Abstract
A process for making a component by depositing a first layer of a powder material in a confined region and then depositing a binder material to selected regions of the layer of powder material to produce a layer of bonded powder material at the selected regions. Such steps are repeated a selected number of times to produce successive layers of selected regions of bonded powder material so as to form the desired component. The unbonded powder material is then removed. In some cases the component may be further processed as, for example, by heating it to further strengthen the bonding thereof.
801 Citations
58 Claims
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1. A process for making a component comprising the steps of
(1) depositing a preselected quantity of a powder material; -
(2) spreading said powder material in a layer of preselected thickness over a predetermined confined region; (3) applying a further material to selected regions of said layer of powder material which will cause said layer of powder material to become bonded at said selected regions; (4) repeating steps (1), (2) and (3) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (5) removing unbonded powder material which is not at said one or more selected regions to provide the component. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A process for making a component comprising the steps of
(1) depositing a layer of powder material; -
(2) applying to selected interior regions of said layer of powder material a further material which will cause said layer of powder material to become bonded at said selected regions and applying said further material also to a preselected peripheral region of said layer which will cause the powder material in said preselected peripheral region to become bonded to form a container region; (3) repeating steps (1) and (2) a selected number of time to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (4) removing said bonded peripheral regions and removing unbonded powder material which is not at said one or more selected regions to provide the component. - View Dependent Claims (11, 12, 13, 14)
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15. A process for making a component comprising the steps of
(1) depositing a layer of a porous material having interconnected porosity, said layer being in the form of a preformed web comprising porous material temporarily held together by a first material; -
(2) applying to one or more selected regions of said layer of porous material a further material which will cause said layer of porous material to become bonded at said one or more selected regions; (3) repeating steps (1) and (2) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (4) removing both said porous material and said first material which are not at said one or more selected regions to provide the component. - View Dependent Claims (16)
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17. Apparatus for making a component, said apparatus comprising:
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a hollow cylinder; a piston which fits within said cylinder with peripheral clearance; means for traversing said piston through said cylinder, said traversing means including means for guiding the travel of said piston independently of said cylinder; means for spreading a layer of a powder material over said piston; and means for applying a bonding material to selected regions of said layer of powder material. - View Dependent Claims (18, 19, 20, 21)
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22. Apparatus for dispensing a train of a powder material, said apparatus comprising:
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a sieve drum which is mounted for rotation around an axis which is inclined from the vertical, said drum having an opening at its upper end, the peripheral wall of said drum being perforate; means for introducing a quantity of said powder material through said opening; and means for rotating said drum around said axis to cause said powder material to be metered out through said peripheral wall. - View Dependent Claims (23, 24, 25, 26)
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27. A process for making a component comprising the steps of
(1) depositing a layer of highly flowable powder material in a confined region; -
(2) applying to said layer a linking material which, at least temporarily, reduces the flowability of said powder material; (3) applying to selected regions of said layer a further material which will cause said layer of powder material to become bonded at said selected regions; (4) repeating steps (1), (2) and (3) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (5) removing unbonded powder material which is not at said one or more selected regions to provide the component. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43)
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44. A process for making a component comprising the steps of
(1) depositing a layer of a powder material in a confined region, said powder material including a first material which, when activated, will temporarily link the particles of powder material to reduce flowability; -
(2) activating said first material; (3) applying a further material to selected regions of said layer of powder material which will cause said layer of powder material to become bonded at said selected regions; (4) repeating steps (1), (2) and (3) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (5) removing both said first material and unbonded powder material which are not in said one or more selected regions thereby to provide the component. - View Dependent Claims (45, 46)
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47. A process for making a component comprising the steps of
(1) depositing in a confined region a layer of a powder material, said powder material including a material which will cause gellation of preselected colloidal suspensions; -
(2) applying a preselected colloidal suspension to selected regions of said layer of powder material thereby to cause said layer of powder material to become bonded at said selected regions; (3) repeating steps (1) and (2) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (4) removing unbonded powder material which is not at said one or more selected regions to provide the component. - View Dependent Claims (48, 49, 50, 51)
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52. A process for making a component comprising the steps of
(1) depositing a preselected quantity of a powder material; -
(2) spreading said powder material in a layer of preselected thickness over a predetermined confined region; (3) compacting said layer to reduce its thickness; (4) applying a further material to selected regions of said layer of powder material which will cause said layer of powder material to become bonded at said selected regions; (5) repeating steps (1) through (4) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (6) removing unbonded powder material which is not at said one or more selected regions to provide the component. - View Dependent Claims (53, 54, 55, 56)
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57. A process for making a component comprising the steps of
(1) placing a powder material in a sieve drum having a perforate peripheral wall; -
(2) rotating and traversing said drum over a predetermined region thereby to deposit a layer of said powder material over said region; (3) applying a further material to selected regions of said layer of powder material which will cause said layer of powder material to become bonded at said selected regions; (4) repeating steps (1), (2) and (3) a selected number of times to produce a selected number of successive layers, said further material causing said successive layers to become bonded to each other; (5) removing unbonded powder material which is not at said one or more selected regions to provide the component. - View Dependent Claims (58)
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Specification