SYSTEM AND METHOD FOR ADDITIVE METAL MANUFACTURING

1 . An additive manufacturing system, comprising:

a build volume;

a material deposition head arranged within the build volume;

a subtractive machining head arranged within the build volume;

a build plate arranged within the build volume underneath the subtractive machining head, wherein the build plate comprises an interfacial material selected to retain a build material during build material manipulation, the interfacial material arranged proximal the subtractive machining head; and

a control system electrically connected to the material deposition head and the subtractive machining head.

2 . The system of claim 1 , wherein the interfacial material comprises an adhesive.

3 . The system of claim 2 , wherein the adhesive comprises at least one of graphite, boron nitride, titania, and silica.

4 . The system of claim 1 , wherein the interfacial material, cooperatively with the build material, generates a layer attachment force that exceeds a shear force exerted on the build material during build material manipulation with the subtractive machining head.

5 . The system of claim 1 , wherein the material deposition head is configured to deposit the interfacial material onto the build plate.

6 . The system of claim 1 , wherein the subtractive machining head is configured to machine the interfacial material.

7 . The system of claim 1 , wherein the material deposition head is configured to deposit the build material over the build plate; and wherein the subtractive machining head is configured to machine the build material.

8 . The system of claim 1 , further comprising a heating chamber configured to:

receive a part precursor, wherein the part precursor is coupled to the build plate by the interfacial material; and

sinter the part precursor to form a physical object.

9 . The system of claim 7 , wherein the interfacial material degrades during sintering, releasing the part precursor from the build plate.

10 . The system of claim 1 , wherein the build plate comprises a carbonaceous material.

11 . A method for forming a physical object from a virtual model comprising:

within a working volume:

providing a build plate comprising an interface layer;

fabricating an object precursor, comprising a geometry corresponding to the virtual model, on the interface layer, wherein fabricating the object precursor comprises iteratively:

depositing a build material layer over the interface layer; and

machining the build material layer, wherein the interface layer retains the build material layer during build material machining; and

sintering the object precursor to form the physical object, wherein the interface layer releases the physical object from the build plate during sintering.

12 . The method of claim 11 , wherein the interface layer comprises an adhesive.

13 . The method of claim 12 , wherein the adhesive comprises at least one of graphite, boron nitride, titania, and silica.

14 . The method of claim 11 , wherein the interface layer retains the build material layer during build material machining with a layer attachment force, generated between the interface layer and the build material layer, that exceeds a shear force generated during machining the build material layer.

15 . The method of claim 11 , further comprising levelling the interface layer.

16 . The method of claim 15 , wherein a level face of the interface layer defines a reference point for fabricating the object precursor with the geometry corresponding to the virtual model.

17 . The method of claim 15 , wherein the interface layer comprises support material, the method further comprising:

depositing a support material layer directly onto the build plate; and

machining the support material layer to level the support material layer.

18 . The method of claim 17 , wherein depositing the support material comprises depositing a raft of support material directly on the build plate.

19 . The method of claim 11 , further comprising transferring the build plate, retaining the object precursor using the interface layer, from the working volume to a furnace, wherein the object precursor is sintered in the furnace.

20 . The method of claim 11 , wherein releasing the physical object from the build plate comprises decomposing the interface layer during sintering.