Method of Creating a Surface Texture

Abstract

A method of creating a texture on at least one surface of a part is disclosed. The part is molded from a feedstock including a powder remaining solid during molding and a binder, and solidified. Then, a physical state of the binder is changed in only a predetermined portion of each surface of the part to be textured. The texture is then created from the predetermined portion by debinding and sintering the part.

1 . A method of creating a texture on at least one surface of a part, the method comprising:
 a) molding the part from a feedstock including a powder remaining solid during molding and a binder, including solidifying the molded part;   b) after step a), changing a physical state of the binder in only a predetermined portion of each of the at least one surface of the part; and   c) after step b), defining the texture from the predetermined portion by debinding and sintering the part.   
     
     
         2 . The method as defined in  claim 1 , wherein the powder is a metal powder. 
     
     
         3 . The method as defined in  claim 1 , wherein step b) includes locally heating only the predetermined portion. 
     
     
         4 . The method as defined in  claim 1 , wherein step b) includes melting the binder in only the predetermined portion. 
     
     
         5 . The method as defined in  claim 1 , wherein step b) includes vaporizing the binder in only the predetermined portion. 
     
     
         6 . The method as defined in  claim 1 , wherein step b) includes avoiding local sintering or chemical alteration of the powder. 
     
     
         7 . The method as defined in  claim 1 , wherein step b) includes displacing the metal powder in the predetermined portion. 
     
     
         8 . The method as defined in  claim 1 , wherein step c) includes creating the texture with a solid loading in the predetermined portion differing from that in a remainder of the part. 
     
     
         9 . The method as defined in  claim 1 , wherein step b) is performed by locally heating the predetermined portion with a laser. 
     
     
         10 . The method as defined in  claim 9 , wherein the laser is configured such as to be out of focus with the at least one surface during the local heating thereof. 
     
     
         11 . The method as defined in  claim 1 , wherein the binder is a mix of thermoplastic polymers. 
     
     
         12 . The method as defined in  claim 1 , wherein the predetermined portion of each of the at least one surface defines a pattern of regularly spaced apart indentations on the surface. 
     
     
         13 . A method of creating a texture on a part, the method comprising:
 providing a solid green part made from a feedstock including a binder;   melting or vaporizing the binder in only a predetermined portion of at least one surface of the green part while the binder in a remainder of the green part remains solid; and   after the binder is melted or vaporized in the predetermined portion, debinding and sintering the part, the predetermined portion after debinding and sintering defining the texture on the at least one surface.   
     
     
         14 . The method as defined in  claim 13 , wherein the binder in the predetermined portion is melted and vaporized. 
     
     
         15 . The method as defined in  claim 13 , wherein the feedstock includes a metal powder and melting or vaporizing the binder is performed by heating the predetermined portion to a temperature lower than a temperature causing local sintering or chemical alteration of the metal powder. 
     
     
         16 . The method as defined in  claim 13 , wherein the feedstock includes a metal powder and melting or vaporizing the binder causes displacement of the metal powder in the predetermined portion. 
     
     
         17 . The method as defined in  claim 13 , wherein melting or vaporizing the binder causes a change in solid loading in the predetermined portion. 
     
     
         18 . The method as defined in  claim 13 , wherein melting or vaporizing the binder is performed by locally heating the predetermined portion with a laser. 
     
     
         19 . The method as defined in  claim 13 , wherein the binder is a mix of thermoplastic polymers. 
     
     
         20 . The method as defined in  claim 13 , wherein the predetermined portion of each of the at least one surface defines a pattern of regularly spaced apart indentations on the surface.