Additively manufactured high temperature objects
Method for producing an object by additively manufacturing a preform of the object from a building material comprising a polymer. The preform is encapsulated with a metal or metal alloy encapsulant that is capable of withstanding temperatures greater than the preform. The encapsulated preform is heated at a predetermined temperature and for a period of time, such that the preform at least partially transmutes into the form of a carbonaceous solid.
1. A method of producing a three-dimensional object, comprising the steps of:
additively manufacturing a preform of a three-dimensional object from a building material selected from the group consisting of a polymer, polyaryletherketone (“PAEK”), carbon fiber, at least 15% carbon fiber by weight, or polyetherketone ketone (“PEKK”);
encapsulating the preform with a metal or metal alloy that is capable of withstanding temperatures greater than the preform;
providing venting holes in the encapsulated preform prior to a step of heating so that solvents may be vented from the encapsulated preform during the step of heating;
heating the encapsulated preform at a predetermined temperature and for a period of time, such that the preform substantially transmutes into a form of a carbonaceous solid residue;
maintaining the preform within an inert gas environment during the heating step;
wherein the step of additively manufacturing the preform of the three-dimensional object from the building material comprises the following steps:
applying a layer of the building material on a bed or on a previously applied layer of the building material in a powder form;
solidifying select points of the layer of the building material by a heat energy introduced by electromagnetic radiation or particle radiation according to a cross-section pattern assigned to layer so that the building material at the select points is solidified by the radiation;
wherein the applying step and the solidifying step are successively repeated until all cross sections of the preform of the object are solidified;
wherein the step of encapsulating the preform comprises the step of applying a nickel plating that is capable of withstanding high temperatures;
wherein the step of heating comprises:
increasing the temperature in the inert gas environment at a controlled rate that minimizes expansion of the preform;
maintaining a temperature in the inert gas environment, after the step of increasing the temperature, between 400 Celsius and 500 Celsius.
2. The method of claim 1 , further comprising a step of closing the venting holes in the metal alloy encapsulant after the step of heating.
3. The method of claim 2 , wherein the step of closing the venting holes is performed in the inert environment.
4. A method of producing a three-dimensional object, comprising the steps of:
additively manufacturing a preform of a three-dimensional object from a building material selected from the group consisting of a polymer, polyaryletherketone (“PAEK”), or carbon fiber;
encapsulating the preform with a metal or metal alloy that is capable of withstanding temperatures greater than the preform;
providing venting holes in the encapsulated preform so that solvents may be vented from the encapsulated preform during a subsequent heating;
heating the encapsulated preform at a predetermined temperature and for a period of time, such that the preform substantially transmutes into a form of a carbonaceous solid residue;
maintaining the preform within an inert gas environment during the heating step;
wherein the step of additively manufacturing the preform of the three-dimensional object from the building material comprises the following steps:
applying a layer of the building material on a bed or on a previously applied layer of the building material in a powder form;
solidifying select points of the layer of the building material by a heat energy introduced by electromagnetic radiation or particle radiation according to a cross-section pattern assigned to layer so that the building material at the select points is solidified by the radiation;
wherein the applying step and the solidifying step are successively repeated until all cross sections of the preform of the object are solidified;
wherein the step of encapsulating the preform comprises the step of applying a nickel plating that is capable of withstanding high temperatures;
wherein the step of heating comprises:
increasing the temperature in the inert gas environment at a controlled rate that minimizes expansion of the preform;
maintaining a temperature in the inert gas environment, after the step of increasing the temperature, at 400 Celsius or greater.
5. The method of claim 4 , wherein the temperature is maintained for a period of time such that the preform substantially transmutes into the form of a carbonaceous solid residue.
6. The method of claim 4 , further comprising a step of closing the venting holes in the metal alloy encapsulant after the step of heating.
7. The method of claim 4 , wherein the step of closing the venting holes is performed in the inert environment.
8. The method of claim 4 , wherein the building material is at least 15% carbon fiber by weight.
9. The method of claim 4 , wherein the building material comprises polyetherketone ketone (“PEKK”).
10. The method of claim 4 , wherein the step of heating comprises:
maintaining a temperature in the inert gas environment, after the step of increasing the temperature, between 400 Celsius and 500 Celsius.