US 11,787,105 B2
Fused filament fabrication of components including predetermined yield points based on composition functions
Quinlan Yee Shuck, Indianapolis, IN (US); Scott Nelson, Carmel, IN (US); Raymond Ruiwen Xu, Carmel, IN (US); Brandon David Ribic, Noblesville, IN (US); and Matthew R. Gold, Carmel, IN (US)
Assigned to Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce North American Technologies, Inc., Indianapolis, IN (US)
Filed by Rolls-Royce Corporation, Indianapolis, IN (US); and Rolls-Royce North American Technologies, Inc., Indianapolis, IN (US)
Filed on Nov. 13, 2020, as Appl. No. 17/97,497.
Claims priority of provisional application 62/935,525, filed on Nov. 14, 2019.
Prior Publication US 2021/0146604 A1, May 20, 2021
Int. Cl. B29C 64/118 (2017.01); B22F 10/28 (2021.01); B33Y 10/00 (2015.01); B29L 31/28 (2006.01); B33Y 70/00 (2020.01); B33Y 80/00 (2015.01); B29K 103/06 (2006.01); B33Y 30/00 (2015.01)
CPC B29C 64/118 (2017.08) [B22F 10/28 (2021.01); B29K 2103/06 (2013.01); B29L 2031/283 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12)] 7 Claims
OG exemplary drawing
 
1. A method for additively manufacturing a component, the method comprising:
forming the component on the major surface of a substrate, wherein the component comprises a region comprising a plurality of overlying metal layers, wherein the metal layers are each derived from a filament comprising a powder comprising a polymeric binder and a metal, and wherein the region has a predetermined yield point selected based on a selected composition function of the component;
forming a first portion of the region, wherein the first portion comprises a first thickness, wherein the first portion further comprises a first cross-sectional shape, and wherein the first portion further comprises a first yield point; and
forming a second portion of the region, wherein the second portion comprises a second thickness that is different from the first thickness, wherein the second portion further comprises a second cross-sectional shape that is different from the first cross-sectional shape, wherein the second portion further comprises a second yield point that is different from the first yield point, and wherein the second portion fails at a predetermined stress level.