US 12,459,196 B2
Patterned filament for fused filament fabrication
Evan Raeker, Ann Arbor, MI (US); Quinlan Yee Shuck, Indianapolis, IN (US); Scott Nelson, Carmel, IN (US); Raymond Ruiwen Xu, Carmel, 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. 12, 2020, as Appl. No. 17/096,112.
Claims priority of provisional application 62/935,380, filed on Nov. 14, 2019.
Prior Publication US 2021/0146603 A1, May 20, 2021
Int. Cl. B29C 67/00 (2017.01); B29C 64/118 (2017.01); B29C 64/393 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01); B33Y 70/10 (2020.01)
CPC B29C 64/118 (2017.08) [B29C 64/393 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12); B33Y 70/10 (2020.01)] 7 Claims
OG exemplary drawing
 
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.