ADDITIVELY MANUFACTURED VERTICAL WALL FROM SLURRY

Abstract

A method of fabricating an object is provided. The method includes depositing a first material between second material such that the second material is at opposite sides of the first material, the first material forming a metal, ceramic, or metal-ceramic. The second material is selectively removable from the first material to reveal sidewalls of the first material so that the first material has a more uniform vertical profile than would be the case if the first material was deposited without the second material.

Claims

1. A method of fabricating an object, comprising: depositing a first material between second material such that the second material is at opposite sides of the first material, the first material forming a metal, ceramic, or metal-ceramic, wherein the second material is selectively removable from the first material to reveal sidewalls of the first material so that the first material has a more uniform vertical profile than would be the case if the first material was deposited without the second material.

2. The method of claim 1, wherein the first material is a slurry.

3. The method of claim 1, wherein the first material is a material slurry.

4. The method of claim 1, wherein the second material is a wax.

5. The method of claim 1, wherein the second material is a plastic.

6. The method of claim 1, wherein the first and second material is deposited in the form of a bead.

7. A method of fabricating an object, comprising: (a) depositing a functional material onto a substrate from a first nozzle to form a first layer of the functional material; (b) depositing a support material onto the substrate from a second and third nozzle, the support material deposited at opposite sides of the functional material on the first layer to shape the functional material; (c) repeating steps (a) and (b) at layers subsequent the first layer; and (d) removing the support material to define a uniform vertical profile of the functional material.

8. The method of claim 7, wherein the functional material is a slurry or material slurry.

9. The method of claim 7, wherein the support material is a wax or plastic.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG. 1 is a cross-sectional diagram illustrating a comparison of green body specimen filament layer heights formed via direct ink writing with varied polymer molecular weight and B.sub.4C solids loading.

[0012] FIG. 2 is a diagram of a three-headed printer nozzle for direct ink writing, according to an aspect of the present invention.

[0013] FIG. 3 is a diagram illustrating a functional material deposited on a substrate with support material deposited on opposite sides thereof, according to an aspect of the present invention.

[0014] FIG. 4 is a diagram illustrating the functional material on the substrate without the support material.

DETAILED DESCRIPTION

[0015] The detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts. However, it will be apparent to those skilled in the art that these concepts may be practiced without these specific details. In some instances, well known components are shown in block diagram form in order to avoid obscuring such concepts.

[0016] The present disclosure relates to a method of additively manufacturing a vertical wall from slurry. The method may utilize a direct ink writing process to deposit first material between second material such that the second material may formed at opposite sides of the first material. The first material upon curing forms a metal, ceramic, or metal-ceramic. The second material may be selectively removable from the first material. The first and second materials may be applied in a manner that causes the first material to have a more uniform vertical profile than would be the case if the first material was deposited without the second material.

[0017] Referring to FIG. 2, a three-headed printer nozzle 200 includes dispensers 202, 204, and 206, each respectively having nozzles 208, 210, and 212 at an end thereof to deposit, for example, a bead forming material onto a substrate 220. The nozzle 210 may be configured to deposit a functional bead material 216 that forms, for example, a metal, ceramic, or metal-ceramic upon curing. The functional bead material 216 may be a slurry or material used with slurry. The nozzles 208 and 212 may be configured to deposit support material 214 and 216 such as, for example, a support wax material or plastic. The support material 214 and 216 may have a viscosity and density similar to the slurry material of the functional bead material 216.

[0018] Referring to FIG. 3, the nozzle 210 deposits the functional material 216 layer by layer onto the substrate 220. The nozzles 208 and 212 may be configured to deposit the support material 214 and 218 concurrently with each deposited layer of the functional material 216 to maintain a uniform vertical profile of the functional material 216. Typically, as layers and layers of the functional material 216 are stacked, the functional material 216 may have a tendency to slump. For instance, the vertical profile of the functional material 216 may appear deformed at various layers. According to an aspect, the nozzles 208 and 212 may be configured to deposit the support material 214 and 218 at each layer of the deposited functional material 216 such that support material 214 and 218 abuts the functional material 216 at opposite sides. In an exemplary embodiment, the support material 214 and 218 may be abutted at opposite sides of the functional material 216 such that there is no space between the materials 214, 216, and 218 throughout the vertical build of the functional material 216 at each layer. In this way, for example, the support material 214 and 218 may be configured to shape the functional material 216 while supporting the functional material 216.

[0019] Referring to FIG. 4, various selective methods of removal may be used to remove the support material 214 and 218 from the functional material 216. For example, when heat is applied to the support material 214 and 218, the support material 214 and 218 may be melted away or disintegrated. As such, a vertical profile of the functional material 216 may be maintained. In another exemplary embodiment, the support material 214 and 218 may include a material that dissolves relative to a material used in the functional material 216 to achieve the vertical profile. For example, the support material 214 and 218 may include a water soluble wax in which case water may be used to remove the support material 214 and 218. The present invention may utilize other selective methods of removal dependent upon the characteristic of the support material 214 and 218 such as, for example, but not limited to, burning and evaporation.

[0020] This written description uses examples to disclose the invention, including the preferred embodiments, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. Aspects from the various embodiments described, as well as other known equivalents for each such aspect, can be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with principles of this application.