Method for manufacturing three-dimensional metal parts using conformable release material

Abstract

A method of manufacturing a three-dimensional metal part using a conformable, easy-to-remove material is disclosed. The invention relates to a method of manufacturing a three-dimensional metal, ceramic and / or cermet part, the method comprising: forming a three-dimensional metal, ceramic and / or cermet part by an additive manufacturing technique; encapsulating the three-dimensional metal, ceramic and / or cermet part in a conformable, easy-to-remove material to form an encapsulated three-dimensional metal, ceramic and / or cermet part; and cold isostatic pressing the encapsulated three-dimensional metal, ceramic and / or cermet part with an incompressible pressure medium in contact with the conformable, easy-to-remove material. Also disclosed are three-dimensional metal, ceramic and / or cermet parts manufactured according to the method.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing three-dimensional metal parts, and more specifically, to three-dimensional metal, ceramic or cermet parts manufactured by additive manufacturing processes and cold isostatic pressing. Background Technology

[0002] Additive manufacturing offers a highly efficient and cost-effective alternative to traditional molding-based article manufacturing techniques. With additive manufacturing, the significant time and expense associated with mold and / or bare-piece construction and other processing can be avoided. Furthermore, additive manufacturing technology enables efficient material utilization by allowing for recycling within the process and eliminating the need for mold lubricants and coolants. Most importantly, additive manufacturing allows for significant article design freedom. Articles with highly complex shapes can be produced without significant cost, allowing for the development and evaluation of a range of article designs before selecting a final design.

[0003] It has recently been discovered that complex geometries manufactured using additive manufacturing techniques can be processed by cold isostatic pressing to increase the green density of the parts. This is accomplished by placing the part in an elastomer bag and filling the bag with a flowable particulate medium that transfers externally applied isostatic pressure to the assembly. The bagging process is time-consuming, requires expensive particulate media, and may damage the parts during bagging. An improved method for increasing the green density of parts manufactured using additive manufacturing techniques is needed. Summary of the Invention

[0004] This document discloses a method for manufacturing three-dimensional metal, ceramic, and / or metal-ceramic parts, the method comprising: forming three-dimensional metal, ceramic, and / or metal-ceramic parts by additive manufacturing technology; encapsulating the three-dimensional metal, ceramic, and / or metal-ceramic parts in a conformal removable material to form encapsulated three-dimensional metal, ceramic, and / or metal-ceramic parts; and subjecting the encapsulated three-dimensional metal, ceramic, and / or metal-ceramic parts to cold isostatic pressing with an incompressible pressurized fluid in contact with the conformal removable material.

[0005] This article also discloses three-dimensional metal, ceramic, and / or ceramic parts manufactured using the methods disclosed herein. Attached Figure Description

[0006] Figure 1 It is an isometric view of an encapsulated three-dimensional cutting insert casting existing in a conformal and easily removable material.

[0007] Figure 2 This is an isometric view of a three-dimensional cutting insert with a conformal and easily removable material coating.

[0008] Figure 3It is an isometric view of an encapsulated three-dimensional end mill casting existing in a conformal and easily removable material.

[0009] Figure 4 This is an isometric view of a three-dimensional end mill with a conformal material coating that is easy to remove. Detailed Implementation

[0010] As described above, the present invention relates to a method for manufacturing a three-dimensional metal, ceramic, and / or metal-ceramic part 100, the method comprising: forming the three-dimensional metal, ceramic, and / or metal-ceramic part 100 by additive manufacturing technology; encapsulating the three-dimensional metal, ceramic, and / or metal-ceramic part 100 in a conformal removable material 200 to form an encapsulated three-dimensional metal, ceramic, and / or metal-ceramic part 100; and subjecting the encapsulated three-dimensional metal, ceramic, and / or metal-ceramic part 100 to cold isostatic pressing with a pressurized fluid in contact with the conformal removable material 200.

[0011] The method of this invention includes forming a three-dimensional part 100 using additive manufacturing technology. The term "additive manufacturing technology" refers to a process for forming a three-dimensional object by continuously adding material layer by layer. This layer-by-layer construction allows for the easy formation of undercuts and complex geometries that were previously impossible or required considerable effort and expense to create using conventional manufacturing methods. The three-dimensional object can be based on a 3D model of a component object, which can be designed electronically as part 100 of an electronic file containing design parameters. Additive manufacturing can also be referred to as 3D printing. The additive manufacturing technology of this invention includes a method for forming a three-dimensional metal, ceramic, or cermet part 100 using metal, ceramic, or cermet powder and optionally a binder.

[0012] As used herein, the term "metal powder" includes metals, metal alloys, metal carbides, metal nitrides, metal borides, and / or metal carbides. Metals may include titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, cobalt, nickel, iron, and their alloys, such as steel, stainless steel, tool steel, nickel-based superalloys, tungsten carbide, WC-Co hard metals, or Co-Cr alloys (e.g., Stellite™ alloys).

[0013] As used herein, “ceramic powder” includes (but is not limited to) SiAlON, silicon carbide, silicon nitride, whisker-reinforced ceramics, alumina, or alumina carbide.

[0014] As used herein, “ceramic powder” includes composite materials comprising ceramic and metallic materials.

[0015] Metal, ceramic, or cermet powders are used as starting materials in powder form. The average particle size of the metal powder is not limited, but may be, for example, at least 0.1 μm, for example, at least 1 μm, for example, at least 10 μm. The average particle size of the metal, ceramic, or cermet powder may be, for example, not more than 200 μm, for example, not more than 100 μm, for example, not more than 50 μm. The average particle size of the metal, ceramic, or cermet powder may be, for example, from 0.1 μm to 200 μm, for example, 1 μm and 100 μm, for example, from 10 μm to 50 μm. The average particle size can be measured using techniques known in the art.

[0016] The three-dimensional part 100 may include a combination of metal, ceramic and / or metal-ceramic powder.

[0017] The adhesive used as a starting material, if present, may include metallic or organic materials. Any suitable adhesive material may be used.

[0018] Any additive manufacturing technology capable of being manipulated to form green articles from metal, ceramic, or cermet powders can be employed. Non-limiting examples of additive manufacturing technologies include binder jetting, directed energy deposition (DED), material extrusion, material jetting, powder bed melting, sheet lamination, and / or photopolymerization curing. Non-limiting examples of powder bed melting processes include, for example, selective laser sintering (SLS), selective laser melting (SLM), direct metal laser melting (DMLS), and electron beam melting (EBM).

[0019] As used herein, “binder jetting” refers to a method of manufacturing components in which liquid binder droplets are selectively jetted onto a powder bed (e.g., metal, ceramic, and / or cermet powder) based on a 3D model of the component; the powder particles are bonded together to form a cross-section; additional powder is deposited, followed by binder deposition to form the next layer of the article, and this process is repeated until the green component is complete. For example, a binder jetting apparatus spreads a layer of metal, ceramic, and / or cermet powder in a build box; a printhead moves over the powder layer to deposit liquid binder according to the design parameters of that layer; the layer is dried; the build box is lowered; a new layer of metal, ceramic, and / or cermet powder is spread, and the process is repeated until the green article (green body) is complete.

[0020] Green bodies formed using additive manufacturing processes such as printing can have a green body density ranging from 35% to 55%. As discussed below, depending on the powder size distribution and the applied pressure, the CIP process can increase the density from 55% to 70%.

[0021] The method of the present invention further includes encapsulating a three-dimensional metal, ceramic and / or metal-ceramic part 100 in a conformable removable material 200 to form an encapsulated three-dimensional metal, ceramic and / or metal-ceramic part 100.

[0022] As used herein, the term "conformable removable material" refers to a material that conforms to the morphology and geometry of the outer surface of the three-dimensional part 100 to prevent contact with the surface and is removable from the three-dimensional part 100.

[0023] The conformal removable material 200 may include any suitable material insoluble in the CIP pressurized fluid. For example, the conformal removable material 200 may include organic polymer materials. Organic polymer materials may include thermoplastic materials, elastomer materials, or combinations thereof. Non-limiting examples of organic polymer materials particularly include alkyd polymers, acrylics, polyepoxides, polyamides, polyurethanes, polyureas, polyethers, polyesters, polyolefins, polyalkylenes (e.g., polyethylene, polypropylene), polysaccharides, poly(meth)acrylates, polystyrene, polyvinyl alcohol, poly(vinyl acetate), polyacrylonitrile, polyimide, polyvinyl butyral, polyvinylpyrrolidone, poly(vinyl chloride), styrene-butadiene rubber, nitrile rubber, polysiloxane rubber, xanthan gum, cellulose acetate, nylon-6, nylon-6,6, polycarbonate, polyethylene terephthalate, polyoxymethylene, polysulfone, and polytetrafluoroethylene. Organic polymer materials may also include copolymers and / or grafted polymers of such polymer materials, as well as combinations of polymers. Specific, non-limiting examples of organic polymer materials include paraffin.

[0024] The properties of these polymers can be suitably tuned to achieve conformability by adding any suitable optional additive materials, such as fillers, plasticizers, antioxidants, biocides, dispersants, flow control agents, surfactants, wetting agents, or any combination thereof. Non-limiting examples of plasticizers include, in particular, phthalates such as diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), di(2-propylheptyl) phthalate (DPHP), diisoundecyl phthalate (DIUP), di-tridecyl phthalate (DTDP), bis(2-ethylhexyl) phthalate (DEHP), dibutyl phthalate (DBP), and phthalic acid esters. Diisobutyl dicarboxylate (DIBP), butyl benzoate (BBP), dipentyl phthalate (DPP), diisopentyl phthalate (DIPP), isopentyl n-pentyl phthalate (PIPP), diisoheptyl phthalate (DIHP), bis(2-methoxyethyl) phthalate (DMeP), and dicyclohexyl phthalate (DCHP); cyclohexanoates, such as 1,2-cyclohexanedi-methyl Di-isononyl terephthalate (DC9CH); terephthalate esters, such as dioctyl terephthalate (DOTP) and dibutyl terephthalate (DBT); adipate esters, such as dioctyl adipate (DOA), diisononyl adipate (DINA), and diisodecyl adipate (DIDA); phosphate esters, such as triphenyl phosphate; dibenzoic acid esters, such as diethyl benzoate (ODEDB) and dipropyl benzoate (OXPD). B); vegetable oils, such as ELO, ESBO and castor oil; sebacate esters, such as dimethyl sebacate (DMS) and dibutyl sebacate (DBS); azelaate esters, such as DIDAz; trimellitate esters, such as tri(2-ethylhexyl) trimellitate (TOTM); citrate esters, such as acetyl tributyl citrate (ATBC); and benzoate esters, such as isononyl benzoate (INB) and isodecanyl benzoate (IDB).

[0025] The conformal removable material 200 may be solid at room temperature (approximately 23°C) and atmospheric pressure and should possess sufficient mechanical properties, such as elasticity, to avoid significant deformation and / or defects that could cause the conformal removable material 200 to crack and / or delaminate, resulting in the surface of the encapsulated three-dimensional part 100 being exposed to a pressurized fluid during CIP. For example, the conformal removable material 200 may have a Young's modulus of at least 0.1 GPa, such as at least 0.3 GPa, at least 0.4 GPa, at least 0.7 GPa, at least 1 GPa, at least 2.5 GPa, at least 3 GPa, or at least 3.5 GPa. The conformal removable material 200 may have a Young's modulus not exceeding 4 GPa, for example, not exceeding 3.5 GPa, not exceeding 3 GPa, not exceeding 2.5 GPa, not exceeding 2 GPa, not exceeding 1.5 GPa, not exceeding 1 GPa, or not exceeding 0.5 GPa. The conformal removable material 200 may have a Young's modulus from 0.1 to 4 GPa, for example, from 0.3 to 3.5 GPa, from 0.4 to 3 GPa, from 0.7 to 2.5 GPa, or from 1 to 2 GPa. The tensile modulus can be measured using techniques known in the art, such as ASTM D 638.

[0026] The ductility and toughness of the conformal removable material 200 must be sufficient to allow the shape of the component to deform and be maintained during the CIP process without cracking, splitting or tearing.

[0027] The conformal removable material 200 can be applied to the entire outer surface of the three-dimensional part 100 to form an encapsulated three-dimensional part 100. The conformal removable material 200 can be applied using any suitable technique. Figure 1 As shown, an exemplary encapsulated three-dimensional part 100 (cutting insert) is cast in a cylindrical mold of conformal removable material 200. Figure 3 As shown, an exemplary encapsulated three-dimensional part 100 (an end mill with an internal cooling channel) is cast in a cylindrical mold of conformal removable material 200.

[0028] In a non-limiting example, encapsulating a three-dimensional metal, ceramic, and / or cermet part 100 in a conformal removable material 200 may include placing the three-dimensional part 100 into a mold and pouring liquid conformal removable material 200 into the mold to encapsulate the three-dimensional part 100 in conformal removable material 200. The conformal removable material 200 may then be allowed to solidify, and the encapsulated three-dimensional part 100 may be removed from the mold (by thermal, chemical, or mechanical means). The mold may have any suitable shape, as long as the entire three-dimensional part 100 is assembled within the mold volume of the mold and in contact with the conformal removable material 200. For example, the mold may be cubic, cuboid, sphere, cylinder, or any other suitable shape. The mold forms a casting of the conformal removable material 200 that contains the three-dimensional part 100. Additionally, the part 100 may have internal channels / flowways that require filling. These channels can be filled with conformal removable material 200 to prevent channel collapse during cold isostatic pressing.

[0029] In a non-limiting example, encapsulating a three-dimensional metal, ceramic, and / or cermet part 100 in a conformal removable material 200 may include applying a molten conformal removable material 200 coating to the outer surface of the three-dimensional part 100, wherein the coating encapsulates the three-dimensional part 100. The coating can be applied by any suitable method. Figure 2 As shown, an exemplary encapsulated three-dimensional part 100 (cutting insert) is coated with a conformal removable material 200. Figure 4 As shown, an exemplary encapsulated three-dimensional part 100 (an end mill with internal cooling channels) is coated with a conformal removable material 200.

[0030] For example, coatings can be applied using conventional techniques such as spraying, brushing, dipping, immersion, or combinations thereof. Alternatively, a sheet of conformal removable material 200 can be applied to the outer surface of the three-dimensional metal, ceramic, and / or cermet part 100 and then melted to adhere tightly to the part 100. Alternatively, coatings can be applied under reduced pressure or in a vacuum. The coating thickness applied using these techniques is not limited but can range, for example, from 1 mm to 3 mm. In addition to the outer surface of the three-dimensional part 100, the part 100 may also have internal channels / passages that require filling. These channels can be filled with conformal removable material 200 to prevent channel collapse during cold isostatic pressing.

[0031] In an alternative example, the coating can be applied via physical vapor deposition (PVD). The application of the PVD coating can be accomplished through a vapor deposition process, in which a vaporization vessel is configured to heat the conformal removable material 200 above its melting point to introduce it as a gaseous phase into the environment. The environment can be inert (e.g., nitrogen or argon) to prevent molecular degradation of the conformal removable material 200. A three-dimensional metallic, ceramic, and / or cermet part 100 can be placed within a portion of a PVD chamber, where the temperature and atmosphere pressure are controlled to promote the condensation of the conformal removable material 200 uniformly distributed on the part 100, thus completely sealing the outer surface. A coating of conformal removable material 200 encapsulating the part 100 is formed. The coating thickness applied by PVD can typically be less than 1 mm. Additionally, the part 100 may have internal channels / flow paths that require filling. These channels can be filled with the conformal removable material 200 to prevent channel collapse during cold isostatic pressing.

[0032] In an alternative example, the coating can be applied by chemical vapor deposition (CVD). The application of a CVD coating can be achieved through a chemical deposition process or a vacuum deposition method, wherein a three-dimensional metal, ceramic, and / or ceramic part 100 is exposed to one or more volatile precursors, which react and / or decompose to form a conformal removable material 200 on the surface of the three-dimensional metal, ceramic, and / or ceramic part 100. Volatile byproducts may also be generated and can be removed by a gas flow through the reaction chamber. A conformal removable material 200 coating encapsulating the part 100 can be established. The coating thickness of a coating applied by CVD can typically be less than 1 mm. Additionally, the part 100 may have internal channels / flow paths that require filling. These channels can be filled with the conformal removable material 200 to prevent channel collapse during cold isostatic pressing.

[0033] The method of the present invention further includes cold isostatic pressing of the encapsulated three-dimensional metal, ceramic and / or metal-ceramic part 100 with an incompressible pressurized fluid of a contact conformal removable material 200.

[0034] Cold isostatic pressing (CIP) is a powder forming process in which bulk density is achieved under isostatic or near-isostatic conditions. CIP typically involves: filling an elastomer mold with powder; placing the filled elastomer mold into a CIP chamber; and filling the chamber with a high-pressure incompressible fluid to apply isostatic or near-isostatic pressure to compress the powder in the mold. The result is a highly compacted product with uniform density. Recent findings include: placing a pre-formed green part into an elastomer bag and filling the bag with a flowable particulate medium (“bagging” process); placing the mold into a CIP chamber; and filling the chamber with a high-pressure incompressible fluid to apply isostatic or near-isostatic pressure to compress the green part. Specifically, the elastomer bag and the incompressible flowable medium transfer the isostatic pressure applied outside the chamber to the green part. This invention eliminates the need for elastomer bags and the bagging process. In practice, the encapsulated three-dimensional metal, ceramic, and / or cermet part 100 can be directly placed into the chamber where pressurized fluid contacts the conformal removable material 200. The conformal removable material 200 allows isostatic or quasi-isostatic pressure to be transferred to the three-dimensional metal, ceramic, and / or cermet part 100 via the conformal removable medium. The conformal removable medium also prevents fluid from contacting the outer surface of the three-dimensional part 100 itself.

[0035] Cold isostatic pressing presses utilize an incompressible pressure-bearing fluid to apply pressure to the system. The incompressible pressure-bearing fluid may include water, oil, or a water / oil emulsion. Cold isostatic pressing can provide pressures from 10 ksi to 60 ksi and can increase the green density of 100 three-dimensional metal, ceramic, and / or cermet parts from approximately 35% to 55% of the theoretical density to approximately 55% to 70% of the theoretical density.

[0036] The method of the present invention may further include removing conformal removable material 200 from the encapsulated three-dimensional metal, ceramic, and / or cermet part 100 after compression and encapsulation of the three-dimensional part 100. The conformal removable material 200 can be removed by any suitable method. Methods for removing the conformal removable material 200 may include chemical, thermal, or mechanical processes, and combinations thereof. For example, removing the conformal removable material 200 may include heating the encapsulated three-dimensional metal, ceramic, and / or cermet part 100 to a temperature above the melting point and / or vaporization point of the conformal removable material 200. The conformal removable material 200 will undergo a physical change to become molten, thereby enabling it to roll or drip along the outer surface of the three-dimensional part 100. Non-limiting examples of mechanical processes for removing the conformal removable material 200 include scraping and sanding. Additionally, the conformal removable material 200 can be removed from channels, for example, by melting the conformal removable material 200. The conformal removable material 200 removed from the encapsulated 3D part 100 can be collected and used to encapsulate the newly formed 3D part 100 in the conformal removable material 200.

[0037] The method of the present invention may further include sintering a three-dimensional metal, ceramic, and / or cermet part 100. As used herein, "sintering" means heating the aforementioned three-dimensional part 100 to 0.7T above the metal powder temperature. m A high temperature (70% of the melting point) promotes sufficient diffusion, thereby eliminating the porous structure in a solid or partially liquid state. Sintering can be performed simultaneously with or after the removal of conformal removable materials.

[0038] The method of this invention can be used to manufacture any three-dimensional metal, ceramic, and / or cermet part 100. For example, the three-dimensional part 100 may include a cutting tool. The cutting tool may include, for example, a drill bit, a reamer, or an end mill. The cutting tool may optionally include internal cooling channels, which increase the complexity of the three-dimensional part 100.

[0039] Accordingly, the present invention also relates to a three-dimensional metal, ceramic and / or cermet part 100 manufactured by the above method.

[0040] Each of the above features and examples, and combinations thereof, is said to be covered by this invention. Therefore, this invention relates to (but is not limited to) the following aspects:

[0041] Aspect 1. A method for manufacturing three-dimensional metal, ceramic, and / or metal-ceramic parts, the method comprising: forming the three-dimensional metal, ceramic, and / or metal-ceramic parts by additive manufacturing technology; encapsulating the three-dimensional metal, ceramic, and / or metal-ceramic parts in a conformal removable material to form an encapsulated three-dimensional metal, ceramic, and / or metal-ceramic part; and subjecting the encapsulated three-dimensional metal, ceramic, and / or metal-ceramic part to cold isostatic pressing with an incompressible pressurized fluid in contact with the conformal removable material.

[0042] Aspect 2. The method of Aspect 1, wherein the additive manufacturing process includes a process of forming the three-dimensional metal, ceramic and / or metal-ceramic part by forming metal, ceramic and / or metal-ceramic powder and optionally a binder.

[0043] Aspect 3. The method of any of the preceding aspects, wherein the additive manufacturing process comprises at least one of the following: binder spraying, directional energy deposition, material extrusion, material spraying, powder bed melting, sheet lamination and / or photopolymerization curing.

[0044] Aspect 4. The method of any of the preceding aspects, wherein the conformal removable material includes an organic polymer material.

[0045] Aspect 5. The method of aspect 4, wherein the organic polymer material includes thermoplastic materials.

[0046] Aspect 6. The method of aspect 4, wherein the organic polymer material includes an elastomer material.

[0047] Aspect 7. The method of aspect 4, wherein the organic polymer material comprises solid paraffin.

[0048] Aspect 8. The method of any of the foregoing aspects, wherein encapsulating the three-dimensional metal, ceramic and / or cermet part in a conformal removable material comprises: placing the three-dimensional metal, ceramic and / or cermet part in a mold and pouring the molten conformal removable material into the mold to encapsulate the three-dimensional metal, ceramic and / or cermet part in the conformal removable material.

[0049] Aspect 9. The method of any one of Aspects 1 to 7 above, wherein encapsulating the three-dimensional metal, ceramic and / or metal-ceramic part in a conformal removable material comprises: applying a coating of the conformal removable material in a molten state to the outer surface of the three-dimensional metal, ceramic and / or metal-ceramic part, wherein the coating encapsulates the three-dimensional metal, ceramic and / or metal-ceramic part.

[0050] Aspect 10.9 of the method wherein the coating is applied by spraying, brushing, dipping and / or immersion, and optionally in a reduced pressure environment or in a vacuum.

[0051] Aspect 11. The method of aspect 9 or 10, wherein the coating has a thickness of 1 mm to 3 mm.

[0052] Aspect 12.9 of the method, wherein the coating is applied by physical vapor deposition.

[0053] Aspect 13. The method of aspect 12, wherein the coating has a thickness of less than 1 mm.

[0054] Aspect 14. The method of any of the preceding aspects, wherein the cold isostatic pressing provides a pressure of 10 ksi to 50 ksi.

[0055] Aspect 15. The method of any of the preceding aspects, wherein the incompressible pressure fluid comprises water, oil, or a water / oil emulsion.

[0056] Aspect 16. The method of any of the foregoing aspects, further comprising removing the conformal removable material from the encapsulated three-dimensional metal, ceramic and / or cermet part after compressing the encapsulated three-dimensional metal, ceramic and / or cermet part.

[0057] Aspect 17. The method of aspect 16, wherein the removal of the conformal removable material includes chemical, thermal, or mechanical processes.

[0058] Aspect 18. The method of aspect 16 or 17, wherein removing the conformal removable material comprises heating the encapsulated three-dimensional metal, ceramic and / or cermet part to a temperature above the melting point of the conformal removable material.

[0059] Aspect 19. The method of aspect 16 or 17, wherein removing the conformable short-lived material comprises: heating the encapsulated three-dimensional metal, ceramic and / or ceramic part to a temperature above the evaporation temperature of the conformable short-lived material.

[0060] Aspect 20. A method of any one of Aspects 16 to 19, wherein the conformable removable material removed from the encapsulated three-dimensional metal, ceramic and / or cermet part is collected and used to encapsulate a newly formed three-dimensional metal, ceramic and / or cermet part in the conformable removable material.

[0061] Aspect 21. The method of any of the foregoing aspects, further comprising sintering the three-dimensional metal, ceramic and / or cermet parts.

[0062] Aspect 22. The method of any of the preceding aspects, wherein the three-dimensional metal, ceramic and / or cermet part includes a metal cutting tool.

[0063] Aspect 23. The method of aspect 22, wherein the metal cutting tool includes an internal cooling channel.

[0064] Aspect 24. A three-dimensional metal, ceramic, and / or cermet part, which is manufactured by any of the methods described in the preceding aspects.

[0065] As used herein, the terms “including / containing” should be understood in the context of this application as synonymous with “comprising” and are therefore open-ended, not excluding the presence of additional undescribed or unlisted elements, materials, stages, or method steps. As used herein, “consisting of” should be understood in the context of this application as excluding the presence of any unspecified elements, materials, stages, or method steps. As used herein, “consisting substantially of” should be understood in the context of this application as including specified elements, materials, stages, or method steps (if applicable), and also including any unspecified elements, materials, stages, or method steps that do not materially affect the basic or novel characteristics of the invention.

[0066] For the purposes of the foregoing description, it should be understood that the invention may employ various alternative variations and sequences of steps, unless explicitly specified otherwise. Furthermore, all figures expressing quantities of ingredients, as used in, for example, the specification and claims, should be understood to be modified in all cases by the term “about.” Therefore, unless stated to the contrary, the numerical parameters presented are approximate values ​​and may vary depending on the desired properties sought to be obtained by the invention. To a minimum, and without attempting to limit the application of the equivalence principle, each numerical parameter should be interpreted at least in light of the number of significant figures reported and by applying general rounding techniques.

[0067] It should be understood that any range of values ​​stated herein inherently includes all subranges contained therein. For example, the range “1 to 10” inherently includes all subranges between the stated minimum value 1 and the stated maximum value 10 (and includes both the stated minimum value 1 and the stated maximum value 10), i.e., a minimum value equal to or greater than 1 and a maximum value equal to or less than 10.

[0068] In this application, unless otherwise specifically stated, the use of the singular includes the plural and the plural encompasses the singular. Additionally, in this application, unless otherwise explicitly stated, the use of “or” means “and / or,” even if “and / or” may be explicitly used in certain circumstances. In this application, unless explicitly and clearly limited to a single referent, the articles “a,” “an,” and “described” include plural referents.

[0069] While specific embodiments of the invention have been described above for illustrative purposes, it will be apparent to those skilled in the art that many variations in the details of the invention may be made without departing from the invention as defined in the appended claims.

[0070] Those skilled in the art will understand that various modifications and alterations can be made based on the above disclosure without departing from the broad inventive concept described and illustrated herein. Accordingly, it should be understood that the above disclosure merely illustrates different exemplary aspects of this application, and that various modifications and alterations can be readily made by those skilled in the art, which fall within the spirit and scope of this application and the appended claims.

Claims

1. A method for manufacturing three-dimensional metal, ceramic, and / or metal-ceramic parts, the method comprising: (a) The three-dimensional metal, ceramic, and / or cermet parts are formed by additive manufacturing processes; (b) Encapsulating the three-dimensional metal, ceramic and / or metal-ceramic part in a conformable removable material to form an encapsulated three-dimensional metal, ceramic and / or metal-ceramic part, wherein encapsulating the three-dimensional metal, ceramic and / or metal-ceramic part in a conformable removable material includes applying a coating by physical vapor deposition; as well as (c) Cold isostatic pressing of the encapsulated three-dimensional metal, ceramic and / or cermet parts using an incompressible pressure fluid that contacts the conformal removable material.

2. The method of claim 1, wherein the additive manufacturing process comprises a process of forming the three-dimensional metal, ceramic, and / or metal-ceramic part by forming metal, ceramic, and / or metal-ceramic powder and optionally a binder.

3. The method according to claim 1, wherein the additive manufacturing process comprises at least one of the following: binder spraying, directional energy deposition, material extrusion, material spraying, powder bed melting, sheet lamination, and / or photopolymerization curing.

4. The method according to claim 1, wherein the conformal removable material comprises an organic polymer material.

5. The method according to claim 4, wherein the organic polymer material comprises a thermoplastic material.

6. The method of claim 4, wherein the organic polymer material comprises an elastomer material.

7. The method according to claim 4, wherein the organic polymer material comprises solid paraffin.

8. The method of claim 1, wherein the coating has a thickness of 1 mm to 3 mm.

9. The method according to claim 1, wherein the coating has a thickness of less than 1 mm.

10. The method of claim 1, wherein the cold isostatic pressing provides a pressure of 10 ksi to 50 ksi.

11. The method of claim 1, wherein the incompressible pressure fluid comprises water, oil, or a water / oil emulsion.

12. The method of claim 1, further comprising removing the conformal removable material from the encapsulated three-dimensional metal, ceramic, and / or cermet part after extruding the encapsulated three-dimensional metal, ceramic, and / or cermet part.

13. The method of claim 12, wherein removing the conformal removable material comprises chemical, thermal, or mechanical processes.

14. The method of claim 12, wherein removing the conformal removable material comprises heating the encapsulated three-dimensional metal, ceramic, and / or cermet part to a temperature above the melting point of the conformal removable material.

15. The method of claim 12, wherein removing the conformal removable material comprises heating the encapsulated three-dimensional metal, ceramic, and / or cermet part to a temperature above the vaporization temperature of the conformal removable material.

16. The method of claim 12, wherein the conformal removable material removed from the encapsulated three-dimensional metal, ceramic, and / or cermet part is collected and used to encapsulate a newly formed three-dimensional metal, ceramic, and / or cermet part in the conformal removable material.

17. The method of claim 1, further comprising sintering the three-dimensional metal, ceramic, and / or cermet part.

18. The method of claim 1, wherein the three-dimensional metal, ceramic, and / or cermet part comprises a metal cutting tool.

19. The method of claim 18, wherein the metal cutting tool includes an internal cooling channel.

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