System and method for additive metal manufacturing
A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.
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 on a surface of the build plate proximal the subtractive machining head; and
a control system electrically connected to the material deposition head and the subtractive machining head; and
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;
wherein the material deposition head is configured to deposit the build material and a support material on the build plate wherein the build material comprises a paste; and wherein the subtractive machining head is configured to machine the build material; and wherein the interfacial material degrades during sintering, releasing the part precursor from the build plate.
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, or 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 build plate comprises a carbonaceous material.
8. The system of claim 1 , wherein the build material comprises less than 8% binder by weight.
9. The system of claim 8 , wherein the build material comprises:
metal scaffold particles having a D50 particle size; and
metal infiltrant particles with a D50 particle size less than 25% of the D50 particle size of the metal scaffold particles.
10. The system of claim 9 , wherein the metal infiltrant particles primarily position in interstitial spaces between the metal scaffold particles.
11. The system of claim 9 , wherein the D50 particle size of the metal scaffold particles is between 10 μm and 20 μm, and wherein the D50 particle size of the metal infiltrant particles is between 2 μm and 10 μm.
12. The system of claim 1 , wherein the build material comprises a solvent.