Granted Patent B2

US 12,459,196 · App. 17/096,112 · Granted Nov 4, 2025

Inventors: Evan Raeker (Ann Arbor, MI); Quinlan Yee Shuck (Indianapolis, IN); Scott Nelson (Carmel, IN); Raymond Ruiwen Xu (Carmel, IN); Matthew R. Gold (Carmel, IN)

Assignees: Rolls-Royce Corporation; Rolls-Royce North American Technologies, Inc.

B29C64/118B29C64/393B33Y10/00B33Y30/00B33Y50/02B33Y70/10

Abstract

Claims (13)

1 . A method comprising:

fused filament fabricating a fused filament fabricated component by delivering a filament including a primary material and a sacrificial first binder, wherein the primary material is distributed in a pattern having a first cross sectional geometry that differs from a second cross sectional geometry defined by the filament, the sacrificial first binder supporting the distribution of the primary material in the pattern having the first cross sectional geometry that differs from the second sectional geometry of the filament, wherein:

the sacrificial first binder comprises a first polymer that is soluble in a solvent that is an alcohol,

the primary material comprises a second binder that comprises a second polymer, and

the second polymer is not soluble in the solvent;

substantially removing, via the solvent, the sacrificial first binder, wherein the removed sacrificial first binder is substantially free of the primary material; and

heating, after substantially removing the sacrificial first binder, the fused filament fabricated component to sinter, at temperatures that avoid melting the filament, the primary material to form a sintered part comprising a metal foam, an alloy foam, or a ceramic foam having cavities.

2 . The method of claim 1 , wherein the primary material comprises a powder, the powder including a metal or an alloy.

3 . The method of claim 1 , wherein the primary material comprises a ceramic powder.

4 . The method of claim 1 , wherein the pattern comprises a regular polygon.

5 . The method of claim 2 , wherein the metal or the alloy includes an alloy that includes 9 to 10.0 wt. % W, 9 to 10.0 wt. % Co, 8 to 8.5 wt. % Cr, 5.4 to 5.7wt. % Al, about 3.0 wt. % Ta, about 1.0 wt. % Ti, about 0.7 wt. % Mo, about 0.5 wt. % Fe, about 0.015 wt. % B, and balance Ni.

6 . The method of claim 3 , wherein the ceramic powder includes silicon carbide (SiC).

7 . The method of claim 1 , wherein the first polymer comprises polystyrene (PS).

Assignments (2)

Continuity (2)

References Cited (127)