Method for making hybrid ceramic/metal, ceramic/ceramic body by using 3d printing process

Abstract

This invention relates to a product and a method of preparing ceramic and/or ceramic hybrid materials through the construction of a printed die. The printed die being made by three dimensional printing or additive manufacturing processes possesses both an external geometry and an internal geometry.

1 . A ceramic composite comprising a ceramic body including external features corresponding to a mold pattern and at least one internal cavity; and at least a second material within the internal cavity that is different than the ceramic body, wherein the geometry of the at least one internal cavity includes at least one of an aspect ratio in the range of 100:1 to 5:1 or a diameter in the range of approximately 0.010 inch to 0.100 inch. 
     
     
         2 . The ceramic composite of  claim 1 , wherein the second material includes a metal insert of a geometry that matches the geometry of the at least one internal cavity. 
     
     
         3 . The ceramic composite of  claim 1 , wherein the second material includes a ceramic material that is different than the ceramic body. 
     
     
         4 . The ceramic composite of  claim 1 , wherein the second material is a rod of alumina or quartz. 
     
     
         5 . The ceramic composite of  claim 4 , wherein the rod includes a ceramic coating that is sintered to the ceramic body such that a sintered bond exists between the ceramic body and the rod and wherein the rod reinforces the ceramic body. 
     
     
         6 . The ceramic composite of  claim 1 , wherein the second material is sintered to the ceramic body such that the first and second materials together form a contiguous structure in which the second material reinforces the ceramic body. 
     
     
         7 . The ceramic composite of  claim 6 , wherein the internal cavity is non-linear. 
     
     
         8 . The ceramic composite of  claim 1 , wherein the internal cavity is non-linear and the geometry of the second material matches the geometry of the at least one internal cavity. 
     
     
         9 . A ceramic composite comprising a ceramic body including external features corresponding to a mold pattern and at least one non-linear internal cavity having an aspect ratio in the range of 100:1 to 5:1; and at least a second material within the internal cavity that is different than the ceramic body, wherein the second material is sintered to the ceramic body such that the first and second materials together form a contiguous structure in which the second material reinforces the ceramic body. 
     
     
         10 . The ceramic composite of  claim 9 , wherein the second material is a ceramic-coated metal or ceramic insert in which the ceramic coating is sintered to the ceramic body. 
     
     
         11 . The ceramic composite of  claim 9 , wherein the second material is an injected ceramic material cured and sintered to the ceramic body. 
     
     
         12 . A ceramic composite comprising a ceramic body including external features corresponding to a mold pattern and at least one internal cavity, the internal cavity having a diameter in the range of 0.010 inch to 0.100 inch; and an insert within the internal cavity that includes at least one material that is different than the ceramic body, wherein the insert is a ceramic-coated rod of alumina, quartz, or metal with the ceramic coating sintered to the ceramic body such that a sintered bond exists between the ceramic body and the rod and wherein the rod reinforces the ceramic body. 
     
     
         13 . The ceramic composite of  claim 12 , wherein the insert is a ceramic-coated alumina rod.