Desktop Metal, Inc.

Massachusetts Institute of Technology

Nihan Tuncer

Brian Kernan

Michael Andrew Gibson

Alexander C Barbati

Animesh Bose

Ricardo Fulop

Mark Sowerbutts

Anastasios John Hart

Christopher Allan Schuh

Richard Remo Fontana

George Hudelson

Nicholas Mykulowycz

Aaron Preston

Jay Tobia

Karl-Heinz Schofalvi

John Reidy

Christopher Craven

Techniques for debinding additively fabricated parts are described that do not require solvent debinding or catalytic debinding, and that may be performed using only thermal debinding in a furnace. As a result, in at least some cases debinding and sintering may take place sequentially within a single furnace. In some embodiments, the techniques may utilize particular materials as binders that allow for a thermal debinding process that does not negatively affect the parts.

Thermal debinding techniques for additive manufacturing and related systems and methods

Embodiments of the present disclosure are drawn to systems and methods for adjusting a three-dimensional (3D) model used in metal additive manufacturing to maintain dimensional accuracy and repeatability of a fabricated 3D part. These embodiments may be used to reduce or remove geometric distortions in the fabricated 3D part. One exemplary method may include: receiving, via one or more processors, a selection made by a user; receiving a 3D model of a desired part; retrieving at least one model constant based on the user's selection; receiving an input of at least one process variable setting from a set of process variable settings; generating transformation factors based on the at least one process variable parameter and the at least one model constant; transforming the 3D model of the desired part based on the transformation factors; and generating processing instructions for fabricating the transformed 3D model of the desired part.

Systems and methods for adjusting a three-dimensional (3D) model during additive manufacturing

A system for generating a user-adjustable furnace profile, comprises a user interface configured to receive one or more materials properties from a user, a processor, and a memory with computer code instructions stored thereon. The memory is operatively coupled to the processor such that, when executed by the processor, the computer code instructions cause the system to implement communicating with a furnace to ascertain one or more thermal processes associated with the furnace, identifying one or more object characteristics associated with an object to be processed by furnace, and determining a thermal processing parameter profile of at least one thermal processing parameter corresponding to each of the thermal processes, based on (i) the one or more part characteristics and (ii) the one or more materials properties, the thermal processing parameter profile characterizing a cycle of the one or more thermal processes.

Method and system for software defined metallurgy

Devices, systems, and methods are directed to binder jetting for forming three-dimensional parts having controlled, macroscopically inhomogeneous material composition. In general, a binder may be delivered to each layer of a plurality of layers of a powder of inorganic particles. An active component may be introduced, in a spatially controlled distribution, to at least one of the plurality of layers such that the binder, the powder of inorganic particles, and the active component, in combination, form an object. The object may be thermally processed into a three-dimensional part having a gradient of one or more physicochemical properties of a material at least partially formed from thermally processing the inorganic particles and the active component of the object.

Binder jetting in additive manufacturing of inhomogeneous three-dimensional parts

Complexity of a geometry of a desired (i.e., target) three-dimensional (3D) object being produced by an additive manufacturing system, as well as atypical behavior of the processes employed by such a system, pose challenges for producing a final version of the desired 3D object with fidelity relative to the desired object. An example embodiment enables such challenges to be overcome as a function of feedback to enable the final version to be produced with fidelity. The feedback may be at least one value that is associated with at least one characteristic of a printed object following processing of the printed object. Such feedback may be obtained as part of a calibration process of the 3D printing system or as part of an operational process of the 3D printing system.

Additive manufacturing system with fabricated support structure facilitating contaminant removal

In a method for forming a shape memory alloy wire a shape memory alloy composition of CuAlMnNi excluding grain refiner elements, is mixed, including between about 20 at % and about 28 at % Al, between about 2 at % and about 4 at % Ni, between about 3 at % and about 5 at % Mn, and Cu as a remaining balance. The mixture is heated between about 1100&#xb0; C. and about 1400&#xb0; C. and ejected from a crucible, at an ejection pressure of between about 3 bar and about 5 bar through a nozzle having a nozzle diameter of between about 200 microns and about 280 microns, to a face of a melt spinning wheel with speed of between about 9 m/s and about 13 m/s until there is formed a shape memory alloy wire having a length of at least about 1.5 meters and a diameter of no more than about 150 microns.

Continuous shape memory alloy wire production by melt spinning

Systems and methods for calibration feedback for additive manufacturing

There is provided herein a shape memory alloy wire that includes an alloy composition of CuAlMnNi and excluding grain refiner elements. The alloy composition includes 20 at %-28 at % Al, 2 at %-4 at % Ni, 3 at %-5 at % Mn with Cu as a remaining balance of the alloy composition. The alloy composition is disposed as an elongated wire of at least about 1 meter in length, having a wire diameter of less than about 150 microns. At least about 50 vol % of said alloy composition along said wire length has an oligocrystalline microstructure as-disposed in the wire and without thermal treatment of the wire.

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Cambridge, MA, United States of America

Nihan Tuncer