Binder jetting in additive manufacturing of inhomogeneous three-dimensional parts
Devices, systems, and methods are directed to binder jetting for forming three-dimensional parts having controlled, macroscopically inhomogeneous material composition. In general, a binder may be delivered to each layer of a plurality of layers of a powder of inorganic particles. An active component may be introduced, in a spatially controlled distribution, to at least one of the plurality of layers such that the binder, the powder of inorganic particles, and the active component, in combination, form an object. The object may be thermally processed into a three-dimensional part having a gradient of one or more physicochemical properties of a material at least partially formed from thermally processing the inorganic particles and the active component of the object.
1. A method for forming an object, comprising:
depositing a first layer of powder along a powder bed, the depositing comprising spreading the layer of powder along the powder bed, the powder including inorganic particles;
depositing, via a first printhead, a first layer of binder along a portion of the first layer of powder, the depositing comprising jetting via the first printhead, the first layer of binder along the first layer of powder;
depositing, via a second printhead, an additive along the first layer of powder and the first layer of binder, the additive including an active component and wherein the additive is selected from the group consisting of chromium, tungsten, manganese, nickel and molybdenum;
forming, with the binder, layer of powder, and the active component, an object; and
thermally processing the object into a three-dimensional part, the three-dimensional part including, in an area corresponding to a distribution of the active component of the object, a physicochemical gradient at least partially formed from thermally processing the inorganic particles and the active component of the object.
2. The method of claim 1 , wherein the method further comprises, before the forming step:
depositing a second layer of powder along the powder bed;
depositing, via the first printhead, a second layer of binder along the second layer of powder, the depositing comprising jetting via the first printhead, the first layer of binder along the first layer of powder;
depositing, via the second printhead, the additive along the second layer of powder and the second layer of binder.
3. The method of claim 1 , wherein the method further comprises placing the active component in a carrier.
4. The method of claim 3 , wherein, upon being placed in the carrier, the active component remains undissolved and suspended in the carrier.
5. The method of claim 3 , wherein the carrier includes a solvent selected from the group consisting of water, an aromatic organic substance, an aliphatic organic substance, alcohol, and a surfactant.
6. The method of claim 5 , wherein the active component is dissolved in the solvent.
7. The method of claim 1 , wherein the thermal processing further comprises chemically reacting the inorganic particles with one or more process gasses.
8. The method of claim 1 , further comprising depositing a second layer of powder.
9. The method of claim 1 , wherein the one or more binders are deposited to the plurality of layers of the powder between formation of successive layers of the plurality of layers of the powder.
10. A method for delivering a plurality of fluids to form an object, comprising:
depositing a first layer of a plurality of layers of a powder along a powder bed, the powder including inorganic particles;
jetting, via a first printhead, a first layer of binder along a portion of the first layer of the powder;
jetting, via a second printhead, an additive along the first layer of the powder, wherein the additive includes one or more of carbon black, graphene, carbon nanotubes, boron or silicon carbide;
forming, with the binder, the layer of powder, and the additive, an object; and
thermally processing the object into a three-dimensional part, the three-dimensional part including, in an area corresponding to a distribution of the additive of the object, a physicochemical gradient at least partially formed from thermally processing the inorganic particles and the additive of the object.
11. The method of claim 10 , wherein the additive is selected from the group consisting of an active component, a salt, and a first polymer and an active component attached to the first polymer.
12. The method of claim 10 , wherein the additive comprises an ink, the ink chemically modifying the binder to form an active component.
13. The method of claim 10 , wherein the inorganic particles include at least one of ceramic particles or metallic particles.
14. The method of claim 10 , wherein the one or more binders include at least one of a polymer, a salt, nanoparticles, or a gel.
15. The method of claim 10 , wherein the first layer of binder include a first binder, the additive further comprising a second binder different from the first binder.