US 11,911,822 B2
Multi-layer composites with varied layer thicknesses and related methods
Thines Kumar Perumal, Singapore (SG); Subhash Guddati, Singapore (SG); Montray Leavy, Singapore (SG); Virendra Warke, North Chelmsford, MA (US); and Devon N. Dion, Nashua, NH (US)
Assigned to ENTEGRIS, INC., Billerica, MA (US)
Filed by ENTEGRIS, INC., Billerica, MA (US)
Filed on Dec. 3, 2021, as Appl. No. 17/541,690.
Claims priority of provisional application 63/125,296, filed on Dec. 14, 2020.
Prior Publication US 2022/0184703 A1, Jun. 16, 2022
Int. Cl. B22F 10/16 (2021.01); B33Y 10/00 (2015.01); B33Y 70/10 (2020.01); B22F 10/28 (2021.01); B33Y 80/00 (2015.01)
CPC B22F 10/16 (2021.01) [B22F 10/28 (2021.01); B33Y 10/00 (2014.12); B33Y 70/10 (2020.01); B33Y 80/00 (2014.12)] 19 Claims
OG exemplary drawing
 
1. A method of forming a three-dimensional body by additive manufacturing steps, the method comprising:
designating a target thickness and a thickness tolerance for the three-dimensional body;
forming multiple solidified coarse feedstock layers, each having a thickness that is greater than a magnitude of the thickness tolerance;
forming at least one solidified fine feedstock layer that has a thickness that is less than the magnitude of the thickness tolerance; and
forming the three-dimensional body from the multiple solidified coarse feedstock layers and the at least one solidified fine feedstock layer,
wherein the three-dimensional body has a measured thickness that differs from the target thickness by not more than the magnitude of thickness tolerance,
wherein forming each solidified coarse feedstock layer and at least one solidified fine feedstock layer comprises:
forming a coarse feedstock layer having a coarse feedstock layer thickness,
solidifying a portion of the coarse feedstock layer to form a solidified coarse feedstock layer having a solidified coarse feedstock layer thickness,
before or after forming the solidified coarse feedstock layer, forming at least one fine feedstock layer having a fine feedstock layer thickness that is less than the coarse feedstock layer thickness, and
solidifying a portion of the at least one fine feedstock layer to form the at least one solidified fine feedstock layer having a solidified fine feedstock layer thickness that is less than the solidified coarse feedstock layer thickness.