Markforged, Inc.

Other

Metal Matrix Cast Composites, Inc.

Maxim Seleznev

Joseph Roy-Mayhew

Gregory Thomas Mark

James A Cornie

Michelle Ling Chao

Benjamin Hodsdon Gallup

Shiyu Zhang

Jessica Faust

Brett M Schulz

Christopher Hoffman

Method of manufacturing a metal matrix composite part and ceramic preform assembly for use in the method. The method includes forming a ceramic preform using 3D printing, sintering the ceramic preform to form a sintered preform, introducing a liquid metal into the sintered preform to form the metal matrix composite part. The ceramic preform may be part of a ceramic preform assembly includes at least one ceramic preform and an infiltrant reservoir connected to the ceramic preform. The method may also include forming the ceramic preform assembly using 3D printing.

Method of manufacturing metal matrix composite parts

Metal composites, tooling and methods of additively manufacturing these are disclosed. Metal objects and structures as provided herein are additively manufactured from metal having an infill pattern infiltrated with a metal powder. Also provided herein are methods of forming such objects and structures. Methods include additively manufacturing a metal structure having an interior printed using an infill. Steps can further include infiltrating the printed infill of the structure with a powder metal thereby forming a composite.

Composites, tooling, dies and methods of manufacturing thereof

A method of manufacturing a part formed of metal, a method of determining a ceramic support structure for the metal part, and an un-sintered metal part including the ceramic support. The method of manufacturing the part includes forming a metal part and forming a ceramic support by depositing a ceramic composite material in a pattern to form ceramic print layers. The ceramic support supports a supportable portion of the metal part. The method of determining the ceramic support structure for the metal part includes determining, (i) a composition of a ceramic filament used to produce the ceramic support or (ii) a geometry of an infill of the ceramic support such that the ceramic support has a strength sufficient to support the supportable portion prior to sintering and is deformable to allow the supportable portion to undergo geometric changes during sintering.

Additive manufacturing process for forming a metal part using ceramic support and bodies formed thereby

A material for producing a three-dimensionally printed part including a metal material and at least one sintering aid in an amount effective to give the three-dimensionally printed part a density of between about 90% and about 100% after sintering is disclosed. A method of printing a three-dimensional part including selecting a metal material, incorporating at least one sintering aid into the metal material to form a print material, and printing the three-dimensional part is also disclosed. A method of producing a sintered metal part including providing a metal material for the sintered metal part incorporating boron as a first sintering aid, incorporating phosphorus as a second sintering aid, forming the metal part in a predetermined form the metal material, and heating the formed metal part to a sintering temperature is also disclosed. Three-dimensionally printed parts are also disclosed.

Methods of increasing density of 3D-printed and sintered parts

Systems, apparatus and methods of additively manufacturing objects are disclosed. Specifically, provided herein are methods of heating objects having a particle-based support at least partially surrounding the object during portions of stages of the heating. Additionally, systems, apparatus, and methods for removing the particle-based support during heating, such that the object can continue heating to form a final part. Systems, apparatus, and methods for distributing the particle-based support to shore the objects through heating are disclosed. Systems, apparatus, and methods for removing the particle-based support are also disclosed herein.

System, apparatus, and methods for managing sintering supports

Surface metallization technology for ceramic substrates is disclosed herein. It makes use of a known phenomenon that many metal&#x2014;metal oxide alloys in liquid state readily wet an oxide ceramic surface and strongly bond to it upon solidification. To achieve high adhesion strength of a metallization to ceramic, a discrete metallization layer consisting of metal droplets bonded to ceramic surface using metal&#x2014;metal oxide bonding process is produced first. Next, a continuous metal layer is deposited on top of the discrete layer and bonded to it using a sintering process. As a result a strongly adhering, glass-free metallization layer directly bonded to ceramic surface is produced. In particular, the process can be successfully used to metalize aluminum nitride ceramic with high thermal and electrical conductivity copper metal.

Continuous or discrete metallization layer on a ceramic substrate

Methods and materials for preparing investment molds useful in pressure infiltration casting of near net-shape metal or metal matrix composite (MMC) components. One embodiment of the invention includes disposing a slurry of an appropriately sized refractory material and a vehicle around a preform or fugitive pattern, removing the bulk of the vehicle, then curing/drying the refractory material to create an investment mold of the invention. Subsequently, pressure infiltration casting with a molten infiltrant using the investment mold permits infiltration of the mold cavity and/or preform without infiltration of the investment mold. As a result, the investment mold readily is removed to provide the near net-shape metal or MMC component. In other embodiments of the invention, a non-fugitive pattern is used, typically with a modified refractory cement of the invention. In these embodiments, the non-fugitive pattern is removed after formation of the investment mold to provide a suitable mold cavity which may be used to produce near net-shape metal or MMC components.

Growing community of inventors

Belmont, MA, United States of America

Maxim Seleznev