IP Library › Granted Patent US 12697661
Granted Patent B2
US 12697661 · App. 18/930,846 · Granted Aug 4, 2026

Multiple additive manufacturing technique material deposition

Inventors: Lawrence Binek (Glastonbury, CT); Jesse Boyer (Middletown, CT); Joseph Ott (Enfield, CT)
Assignee: RTX CORPORATION
B22F12/37B22F10/25B22F2301/10B33Y10/00B33Y80/00C23C24/04
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Quick Facts
Patent No.
US 12697661
App. No.
18/930,846
Granted
Aug 4, 2026
Kind
B2
Abstract

A method of making a metallic component includes mounting a polymeric scaffold onto a mandrel, wherein the mandrel includes one or more chucks configured to secure the polymeric scaffold onto the mandrel and wherein the mandrel is configured to rotate the polymeric scaffold; depositing, with a second additive manufacturing (AM) technique using a material applicator, a component material onto the polymeric scaffold to form the metallic component on the polymeric scaffold, wherein the component has a shape that is the same as the polymeric scaffold; removing the polymeric scaffold; and the metallic component deposited on the polymeric scaffold from the mandrel; and removing the polymeric scaffold from the metallic component.

Claims (17)

1 . A method of making a metallic component, comprising the steps of:

mounting a polymeric scaffold onto a mandrel, wherein the mandrel includes one or more chucks configured to secure the polymeric scaffold onto the mandrel and wherein the mandrel is configured to rotate the polymeric scaffold;

depositing, with a second additive manufacturing (AM) technique using a material applicator, a component material onto the polymeric scaffold to form the metallic component on the polymeric scaffold, wherein the component has a shape that is the same as the polymeric scaffold;

removing the polymeric scaffold and the metallic component deposited on the polymeric scaffold from the mandrel; and

removing the polymeric scaffold from the metallic component.

2 . The method of claim 1 , further comprising the step of:

building, using a first AM technique, the polymeric scaffold.

3 . The method of claim 2 , wherein the first AM technique is material extrusion (MEX).

4 . The method of claim 1 , wherein the polymeric scaffold is formed in the shape of a gas turbine engine combustor liner.

5 . The method of claim 4 , wherein the polymeric scaffold includes one or more apertures.

6 . The method of claim 4 , wherein the second AM technique is cold spray and the component material is copper or a copper alloy.

7 . The method of claim 6 , wherein the polymeric scaffold includes an inner bore configured to define a combustion chamber of the combustor liner when the component material is deposited onto the polymeric scaffold.

8 . The method of claim 7 , wherein the material applicator includes a moveable spray head that is configured to bend at least 90° to permit the component material to be deposited onto the inner bore of the polymer scaffold.

9 . The method of claim 1 , wherein the mandrel is removed from the polymeric scaffold after the metallic component is formed on the polymeric scaffold.

10 . The method of claim 9 , wherein the polymeric scaffold is removed from the metallic component after the mandrel is removed from the polymeric scaffold.

11 . The method of claim 10 , wherein the polymeric scaffold is removed from the metallic component using a chemical reagent.

12 . The method of claim 10 , wherein the polymeric scaffold is removed from the metallic component using a thermal removal process.