Bonded abrasive articles and methods of manufacture

1 . A method of forming an abrasive article, comprising:

depositing a layer of an abrasive mixture onto a dispensing surface from an abrasive mixture dispenser at an abrasive mixture depositing location;

moving the dispensing surface from the abrasive mixture depositing location to a leveling location;

leveling the layer of the abrasive mixture at the leveling location, which is separate from the abrasive mixture depositing location, using a leveling tool, such that the layer has a substantially smooth surface;

moving the dispensing surface from the leveling location to a liquid dispensing station;

applying a liquid material from a liquid dispenser at the liquid dispensing station, which is separate from the abrasive mixture depositing location and separate from the leveling location to the compacted layer of abrasive mixture;

moving the dispensing surface from the liquid dispensing station to a setting station;

allowing the layer of abrasive mixture and dispensed liquid to set at the setting station, which is separate from the abrasive mixture depositing location, separate from the leveling location and separate from the setting station;

repeating the steps of depositing, leveling, applying and setting to form a multilayered abrasive article.

2 . The method of claim 1 further comprising compacting the layer of the abrasive mixture, using a compacting tool at a compacting location, such that a density of the layer of abrasive mixture increases.

3 . The method of claim 2 , wherein the abrasive mixture dispenser, the leveling tool, the compacting tool, the liquid dispenser and the setting station are parts of a first modular assembly.

4 . The method of claim 1 , wherein the applied liquid material is a temporary binder configured to be burnt out during later processing of the abrasive article.

5 . The method of claim 1 , wherein the abrasive mixture comprises a permanent binder precursor, and the permanent binder precursor is configured to be activated during later processing of the abrasive article.

6 . The method of claim 1 , wherein the applied liquid material is a reactive agent that reacts with a compound of the abrasive mixture.

7 . The method of claim 1 , wherein the liquid material is applied in a pattern on the layer of abrasive mixture such that at least a portion of the layer receives no liquid material.

8 . The method of claim 7 , wherein the liquid material is applied in subsequent layers in a pattern such that a channel is formed through the abrasive article.

9 . The method of claim 8 , wherein the channel is an arcuate, tortuous or straight channel extending at least partway through the abrasive article.

10 . A system for forming an abrasive article, comprising:

a workspace;

an abrasive material dispenser that deposits a layer of abrasive material onto the workspace, while the workspace is at a dispensing position;

a leveler that levels a surface of abrasive material on the workspace, while the workspace is at a leveling position;

a binder jet printer that dispenses a liquid binder onto the layer of abrasive material, while the workspace is at a printing position;

wherein the dispensing position, the leveling position, and the printing position are in physically separate locations from one another; and

wherein the workspace is on a moving surface that moves the workspace between the dispensing position under the dispenser, the leveling position under the leveler, and the printing position under the printer.

11 . The system of claim 10 , further comprising a setting station that at least partially dries the liquid binder.

12 . The system of claim 11 , wherein the abrasive material dispenser, leveler, and setting station remain substantially in place with respect to each other.

13 . The system of claim 10 , wherein the leveler is at an adjustable height with respect to the workspace.

14 . The system of claim 10 , further comprising a densification station and wherein the densification station comprises one of: a rotating compactor, a stamper, or a vibratory unit.

15 . The system of claim 10 , further comprising a magnetic orientation unit configured to orient particles within the layer of abrasive material.

16 . An additive manufacturing system, comprising:

a printing workspace;

a series of printing assemblies;

wherein each of the printing assemblies is a modular printing assembly,

wherein each of the modular printing assembly comprises a particle dispensing unit and a liquid dispensing unit;

wherein the particle dispensing unit and the liquid dispensing unit of each of the printing assemblies are at physically separate locations from one another;

wherein the printing workspace moves relative to the series of printing assemblies;

wherein each of the series of printing assemblies deposits a layer of an abrasive mixture on the printing workspace and each of the series of printing assemblies deposits liquid on the abrasive mixture, such that, after the printing workspace passes through the series of printing assemblies, an abrasive article is formed.

17 . The system of claim 16 , wherein the printing workspace is coupled to a movement mechanism such that the printing workspace moves under each of the printing assemblies.

18 . The system of claim 16 , wherein at least one of the modular printing assemblies includes a densification unit.

19 . The system of claim 16 , further comprising an orientation station configured to impart an orientation to particles of the abrasive mixture dispensed by the particle dispensing unit.