System and method for additive metal manufacturing

Abstract

A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.

We claim: 
     
         1 . An additive manufacturing system, comprising:
 a build volume;   a material deposition head arranged within the build volume;   a subtractive machining head arranged within the build volume;   a build plate arranged within the build volume underneath the subtractive machining head, wherein the build plate comprises an interfacial material selected to retain a build material during build material manipulation, the interfacial material arranged proximal the subtractive machining head; and   a control system electrically connected to the material deposition head and the subtractive machining head.   
     
     
         2 . The system of  claim 1 , wherein the interfacial material comprises an adhesive. 
     
     
         3 . The system of  claim 2 , wherein the adhesive comprises at least one of graphite, boron nitride, titania, and silica. 
     
     
         4 . The system of  claim 1 , wherein the interfacial material, cooperatively with the build material, generates a layer attachment force that exceeds a shear force exerted on the build material during build material manipulation with the subtractive machining head. 
     
     
         5 . The system of  claim 1 , wherein the material deposition head is configured to deposit the interfacial material onto the build plate. 
     
     
         6 . The system of  claim 1 , wherein the subtractive machining head is configured to machine the interfacial material. 
     
     
         7 . The system of  claim 1 , wherein the material deposition head is configured to deposit the build material over the build plate; and wherein the subtractive machining head is configured to machine the build material. 
     
     
         8 . The system of  claim 1 , further comprising a heating chamber configured to:
 receive a part precursor, wherein the part precursor is coupled to the build plate by the interfacial material; and   sinter the part precursor to form a physical object.   
     
     
         9 . The system of  claim 7 , wherein the interfacial material degrades during sintering, releasing the part precursor from the build plate. 
     
     
         10 . The system of  claim 1 , wherein the build plate comprises a carbonaceous material. 
     
     
         11 . A method for forming a physical object from a virtual model comprising:
 within a working volume:
 providing a build plate comprising an interface layer; 
 fabricating an object precursor, comprising a geometry corresponding to the virtual model, on the interface layer, wherein fabricating the object precursor comprises iteratively:
 depositing a build material layer over the interface layer; and 
 machining the build material layer, wherein the interface layer retains the build material layer during build material machining; and 
 
   sintering the object precursor to form the physical object, wherein the interface layer releases the physical object from the build plate during sintering.   
     
     
         12 . The method of  claim 11 , wherein the interface layer comprises an adhesive. 
     
     
         13 . The method of  claim 12 , wherein the adhesive comprises at least one of graphite, boron nitride, titania, and silica. 
     
     
         14 . The method of  claim 11 , wherein the interface layer retains the build material layer during build material machining with a layer attachment force, generated between the interface layer and the build material layer, that exceeds a shear force generated during machining the build material layer. 
     
     
         15 . The method of  claim 11 , further comprising levelling the interface layer. 
     
     
         16 . The method of  claim 15 , wherein a level face of the interface layer defines a reference point for fabricating the object precursor with the geometry corresponding to the virtual model. 
     
     
         17 . The method of  claim 15 , wherein the interface layer comprises support material, the method further comprising:
 depositing a support material layer directly onto the build plate; and   machining the support material layer to level the support material layer.   
     
     
         18 . The method of  claim 17 , wherein depositing the support material comprises depositing a raft of support material directly on the build plate. 
     
     
         19 . The method of  claim 11 , further comprising transferring the build plate, retaining the object precursor using the interface layer, from the working volume to a furnace, wherein the object precursor is sintered in the furnace. 
     
     
         20 . The method of  claim 11 , wherein releasing the physical object from the build plate comprises decomposing the interface layer during sintering.