Method for supporting a fabricated object

Abstract

A support structure is fabricated below a printed object to form a structure that prevents or minimizes a drag on a floor while the object shrinks during sintering.

What is claimed is: 
     
         1 . A method comprising:
 fabricating a support structure for an object from a support material, the support structure providing a physical support to support a horizontal surface including at least one of a bridge and an overhang of an object during printing and sintering of the object;   fabricating the object above the support structure from a build material that shrinks similarly to the support material, the build material including a metal powder sinterable into a final dense part and a binder system that carries the metal powder into position within a print and retains the metal powder in a net shape produced by a printer, wherein the support structure includes a structure to prevent or minimize a drag on a floor while the object shrinks during sintering;   fabricating a non-sinterable layer between the object and the support structure;   debinding the object and the support structure; and   sintering the object and the support structure.   
     
     
         2 . The method of  claim 1  wherein the non-sinterable layer includes a ceramic. 
     
     
         3 . A method comprising:
 fabricating a support structure for an object from a support material, the support structure positioned below the object and providing a structure to prevent or minimize a drag on a floor while the object shrinks during sintering;   fabricating the object above the support structure from a build material that shrinks similarly to the support material, the build material including a metal powder sinterable into a final dense part and a binder system that carries the metal powder into position within a print and retains the metal powder in a net shape produced by a printer, wherein the support structure includes a structure to prevent or minimize a drag on a floor while the object shrinks during sintering;   debinding the object and the support structure; and   sintering the object and the support structure.   
     
     
         4 . The method of  claim 3  further comprising fabricating a non-sinterable layer between the object and the support structure. 
     
     
         5 . The method of  claim 3  further comprising fabricating an interface layer of an interface material between the object and the support structure. 
     
     
         6 . The method of  claim 5  wherein the interface material includes a ceramic. 
     
     
         7 . The method of  claim 5  wherein the interface material does not sinter under time and temperature conditions used to sinter the build material. 
     
     
         8 . A method comprising:
 fabricating a support structure for an object from a support material, the support structure providing a physical support during printing and sintering of an object; and   fabricating the object above the support structure from a build material that shrinks similarly to the support material, the build material including a metal powder sinterable into a final dense part and a binder system that carries the metal powder into position within a print and retains the metal powder in a net shape produced by a printer, wherein the support structure includes a structure to prevent or minimize a drag on a floor while the object shrinks during sintering.   
     
     
         9 . The method of  claim 8  further comprising fabricating an interface layer of an interface material between the object and the support structure, the interface material including a ceramic. 
     
     
         10 . The method of  claim 9  wherein the interface material does not sinter under time and temperature conditions used to sinter the build material. 
     
     
         11 . The method of  claim 9  wherein fabricating the support structure includes fabricating a side support providing vertical support to the object. 
     
     
         12 . The method of  claim 9  wherein fabricating the support structure includes fabricating the support structure to support a horizontal surface of the object. 
     
     
         13 . The method of  claim 9  wherein fabricating the support structure includes fabricating the support structure to support the object where there is no underlying physical surface of the object upon which the build material can be deposited during fabrication. 
     
     
         14 . The method of  claim 9  further comprising remove the support structure after fabricating the object. 
     
     
         15 . The method of  claim 9  further comprising removing the support structure before sintering the object. 
     
     
         16 . The method of  claim 9  wherein fabricating the support structure includes fabricating a sintering support that is left attached to object until sintering is completed. 
     
     
         17 . The method of  claim 9  wherein fabricating the support structure includes fabricating the support structure to support at least one of a bridge and an overhang in the object. 
     
     
         18 . The method of  claim 9  wherein fabricating the support structure includes fabricating a structure to prevent or minimize drag on a floor while the object shrinks during sintering. 
     
     
         19 . The method of  claim 9  wherein the binder system has a metal loading of at least fifty percent by volume of the metal powder. 
     
     
         20 . The method of  claim 9  wherein fabricating the object includes depositing the build material with a fused filament fabrication process. 
     
     
         21 . The method of  claim 9  wherein the metal powder has an average diameter between about five microns and about eighty microns.