US 12,005,501 B2
Additive manufacturing process for forming a metal part using ceramic support and bodies formed thereby
Maxim Seleznev, Arlington, MA (US); and Joseph Roy-Mayhew, Watertown, MA (US)
Assigned to Markforged, Inc., Waltham, MA (US)
Filed by Markforged, Inc, Watertown, MA (US)
Filed on Dec. 29, 2022, as Appl. No. 18/147,987.
Claims priority of provisional application 63/358,643, filed on Jul. 6, 2022.
Prior Publication US 2024/0009737 A1, Jan. 11, 2024
Int. Cl. B22F 10/38 (2021.01); B22F 1/10 (2022.01); B22F 10/10 (2021.01); B22F 10/34 (2021.01); B22F 10/64 (2021.01); B22F 10/85 (2021.01); B28B 1/00 (2006.01); B32B 15/04 (2006.01); B33Y 10/00 (2015.01); B33Y 40/20 (2020.01); B33Y 50/02 (2015.01); B33Y 80/00 (2015.01)
CPC B22F 10/38 (2021.01) [B22F 1/10 (2022.01); B22F 10/10 (2021.01); B22F 10/34 (2021.01); B22F 10/64 (2021.01); B22F 10/85 (2021.01); B28B 1/001 (2013.01); B32B 15/04 (2013.01); B33Y 10/00 (2014.12); B33Y 40/20 (2020.01); B33Y 50/02 (2014.12); B33Y 80/00 (2014.12); B22F 2998/10 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of manufacturing a metal part, comprising:
depositing a metal composite material in a pattern to form layers of the metal part, the metal composite material including sinterable metal particles, the metal part including a supportable portion; and
depositing a ceramic composite material to form a ceramic support for the metal part, the ceramic support being deposited in a position to support the supportable portion and be in contact with the supportable portion, the ceramic composite material having a strength to support the supportable portion prior to sintering and being deposited in a geometry that is deformable by the supportable portion to allow the supportable portion to undergo geometric changes during sintering.