Support structure for laminated metal parts

Abstract

A method for additive manufacturing of an object, and a system for manufacturing an object, the method including: depositing a first foil layer, the first foil layer including a first body section, a first support section connected to the first body section, and a second support section connected to the first body section; depositing a second foil layer, the second foil layer comprising the second body section, a third support section, and a fourth support section; aligning the second foil layer with the first foil layer; and applying at least one of heat and pressure to the first foil layer and the second foil layer to form an object comprising the first body section and the second body section.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 020,070, filed May 5, 2020, the entire disclosure of which is hereby incorporated by reference as if set forth herein in its entirety. (Technical field)

[0002] The embodiments described herein relate to methods and systems for fabricating objects, and more particularly, but not exclusively, to methods and systems that use additive manufacturing of foil layers with structural support to form objects. [Background technology]

[0003] Support structures ensure that additively manufactured parts remain dimensionally accurate and reproducible during the manufacturing process. Typically, support generation strategies are optimized for a specific additive manufacturing process. In traditional laminate object manufacturing ("LOM"), adhesives are used to bond sheets together. This is sufficient for plastic and paper laminate object manufacturing, as plastic and paper parts are typically not subjected to high forces or loads.

[0004] Optimization for a specific process requires planning for each individual additively manufactured part. Conversely, implementing a global support strategy allows more complex parts to be manufactured using fewer design rules.

[0005] In the metal sintering process, supports are created to support one end of the metal part during the heating process, preventing distortion of the part before sintering. During sintering, metal parts are weak and can easily distort through friction and gravity. The sintering support may need to be manually removed to prevent further distortion; the part may still shrink 15-20% through friction and gravity while sintering. The support counteracts gravity and can shrink along with the part. Friction within the base can also prevent uniform shrinkage during sintering. The support can also prevent pressure or even heat from being applied across the metal body part.

[0006] Therefore, there is a need for methods and systems for improving additive manufacturing processes. Summary of the Invention [Means for solving the problem]

[0007] This Summary is provided to introduce some concepts in a simplified form that are further described below in the Detailed Description section. This Summary is not intended to identify or exclude key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0008]

[0006] Embodiments according to one aspect relate to a method for additive manufacturing of an object. In some embodiments, the method includes depositing a first foil layer, the first foil layer comprising a first object region and a first support region connected to the first object region, depositing a second foil layer, the second foil layer comprising a second object region and a second support region, and forming an object section including the first object region and the second object region.

[0009] In some embodiments, the first support region and the second support region are configured to uniformly distribute at least one of temperature and pressure to the object segment.

[0010] In some embodiments, the method further includes depositing a constraining material comprising carbon on at least one of the first foil layer or the second foil layer.

[0011] In some embodiments, the method further comprises depositing at least two additional foil layers between the first foil layer and the second foil layer.

[0012] In some embodiments, the second foil layer is spot welded onto the first foil layer.

[0013] In some embodiments, the method further includes attaching a second object region to the first object region, wherein the attached second object region and the first object region form an object segment, and attaching a second support region to the first support region, wherein the attached second support region and the first support region form a support segment.

[0014] In some embodiments, the first support section is subdivided to facilitate piecewise removal from the object section.

[0015] In some embodiments, the method further includes a third support region connected to the first object region and a fourth support region connected to the second object region. In some embodiments, the method further includes attaching the second object region to the first object region, where the attached second object region and first object region form an object section, attaching the second support region to the first support region, where the attached second support region and first support region form the first support section, and attaching the third support region to the fourth support region, where the attached third support region and fourth support region form the second support section.

[0016] In some embodiments, the first and second support segments are configured to distribute temperature and pressure evenly to the object through the first and second foil layers.

[0017] In some embodiments, the first support segment and the second support segment are configured to prevent deformation of the object segment after initial deposition.

[0018] In some embodiments, the first support region is connected to the first object region using a foil connecting bridge configured to increase the structural integrity of the first foil layer.

[0019] In some embodiments, the method further includes removing the foil connecting bridge from the first object region.

[0020] In some embodiments, the method further includes depositing an inhibitor material on the first foil layer, the inhibitor material including at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon.

[0021] In some embodiments, the first foil layer and the second foil layer comprise aluminum.

[0022] In some embodiments, the method further includes aligning the second foil layer and the first foil layer by a first alignment feature in the first foil layer to a second alignment feature in the second foil layer.

[0023] In some embodiments, the first alignment feature and the second alignment feature comprise at least one of a hole, a slot, or a tab pattern.

[0024] In some embodiments, the first foil layer and the second foil layer are deposited using additive manufacturing.

[0025] In some embodiments, the first support region is connected to the first object region using a connecting bridge configured to increase the structural integrity of the first foil layer.

[0026] In some embodiments, the connecting bridge comprises at least one of a polymer or a wax.

[0027] In some embodiments, the method further includes forming the connecting bridge into a curved shape to allow the first object region and the first support region to move relative to one another.

[0028] In some embodiments, the method further comprises selectively heating and melting the bridge by applying an electric current.

[0029] In some embodiments, the method further comprises dissolving the bridge with a solvent.

[0030] In another aspect, embodiments relate to a system for additive manufacturing of an object. In some embodiments, the system includes an additive manufacturing device configured to deposit a first foil layer, the first foil layer comprising a first object region and a first support region connected to the first object region, and deposit a second foil layer, the second foil layer comprising a second object region and a second support region, and an attachment mechanism configured to form an object section including the first object region and the second object region.

[0031] In some embodiments, the first support region and the second support region are configured to uniformly distribute at least one of temperature and pressure to the object segment.

[0032] In some embodiments, the additive manufacturing device is further configured to deposit a constraining material comprising carbon onto at least one of the first foil layer or the second foil layer.

[0033] In some embodiments, the additive manufacturing device is further configured to deposit at least two additional foil layers between the first foil layer and the second foil layer.

[0034] In some embodiments, the additive manufacturing device is configured to spot deposit a second foil layer onto the first foil layer.

[0035] In some embodiments, the attachment mechanism is further configured to attach a second object region to the first object region, where the attached second object region and first object region form an object segment, and to attach a second support region to the first support region, where the attached second support region and first support region form a support segment.

[0036] In some embodiments, the first support section is subdivided to facilitate piecewise removal from the object section.

[0037] In some embodiments, the system further comprises a third support region connected to the first object region and a fourth support region connected to the second object region.

[0038] In some embodiments, the attachment mechanism is further configured to attach a second object region to the first object region, where the attached second object region and first object region form an object segment; attach a second support region to the first support region, where the attached second support region and first support region form the first support segment; and attach a third support region to a fourth support region, where the attached third support region and fourth support region form the second support segment.

[0039] In some embodiments, the first and second support segments are configured to distribute temperature and pressure evenly to the object through the first and second foil layers.

[0040] In some embodiments, the first support segment and the second support segment are configured to prevent deformation of the object segment after initial deposition.

[0041] In some embodiments, the first support region is connected to the first object region using a foil connecting bridge configured to increase the structural integrity of the first foil layer.

[0042] In some embodiments, the foil connecting bridge is configured to be removed from the first object region.

[0043] In some embodiments, the additive manufacturing device is further configured to deposit an inhibitor material on the first foil layer, the inhibitor material comprising at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon.

[0044] In some embodiments, the first foil layer and the second foil layer comprise aluminum.

[0045] In some embodiments, the system further includes an alignment mechanism configured to align the second foil layer and the first foil layer by a first alignment feature in the first foil layer to a second alignment feature in the second foil layer.

[0046] In some embodiments, the first alignment feature and the second alignment feature include at least one of a hole, a slot, or a tab pattern.

[0047] In some embodiments, the first support region is connected to the first object region using a connecting bridge configured to increase the structural integrity of the first foil layer.

[0048] In some embodiments, the connecting bridge comprises at least one of a polymer or a wax.

[0049] In some embodiments, the connecting bridge is in a bent configuration to allow the first object region and the first support region to move relative to one another.

[0050] In some embodiments, the system further includes a device configured to apply an electric current to selectively heat and melt the bridges.

[0051] In some embodiments, the system further includes a solvent applicator configured to apply a solvent to the bridge and dissolve the bridge with the solvent. The present invention provides, for example, the following items. (Item 1) 1. A method for additive manufacturing of an object, the method comprising: depositing a first foil layer, the first foil layer comprising a first object region and a first support region connected to the first object region; depositing a second foil layer, the second foil layer comprising a second object region and a second support region; forming an object section comprising the first object region and the second object region; A method comprising: (Item 2) Item 10. The method of item 1, wherein the first support area and the second support area are configured to uniformly distribute at least one of temperature and pressure to the object segment. (Item 3) Item 10. The method of item 1, further comprising depositing a constraining material comprising carbon on at least one of the first foil layer or the second foil layer. (Item 4) Item 10. The method of claim 1, further comprising depositing at least two additional foil layers between the first foil layer and the second foil layer. (Item 5) Item 10. The method of claim 1, wherein the second foil layer is spot welded onto the first foil layer. (Item 6) attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support area to the first support area, the attached second support area and the first support area comprising a support section; Item 1, the method of claim 1 further comprising: (Item 7) Item 7. The method of item 6, wherein the first support segment is subdivided to facilitate piecewise removal from the object segment. (Item 8) Item 10. The method of item 1, further comprising a third support region connected to the first object region and a fourth support region connected to the second object region. (Item 9) attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support region to the first support region, the attached second support region and the first support region comprising a first support section; 、 attaching the third support region to the fourth support region, the attached third support region and the fourth support region comprising a second support section; Item 9. The method of item 8, further comprising: (Item 10) 10. The method of claim 9, wherein the first support section and the second support section are configured to uniformly distribute temperature and pressure to the object through the first foil layer and the second foil layer. (Item 11) Item 10. The method of item 9, wherein the first support section and the second support section are configured to prevent deformation of the object section after initial deposition. (Item 12) Item 10. The method of item 1, wherein the first support region is connected to the first object region using a foil connecting bridge configured to increase the structural integrity of the first foil layer. (Item 13) Item 13. The method of item 12, further comprising removing the foil connecting bridge from the first object region. (Item 14) 2. The method of claim 1, further comprising depositing an inhibiting material on the first foil layer, the inhibiting material comprising at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon. (Item 15) Item 10. The method of claim 1, wherein the first foil layer and the second foil layer comprise aluminum. (Item 16) 2. The method of claim 1, further comprising aligning the second foil layer and the first foil layer by a first alignment feature in the first foil layer to a second alignment feature in the second foil layer. (Item 17) Item 17. The method of item 16, wherein the first alignment feature and the second alignment feature comprise at least one of a hole, a slot, or a tab pattern. (Item 18) Item 10. The method of claim 1, wherein the first foil layer and the second foil layer are deposited using additive manufacturing. (Item 19) Item 10. The method of item 1, wherein the first support region is connected to the first object region using a connecting bridge configured to increase the structural integrity of the first foil layer. (Item 20) 20. The method of claim 19, wherein the connecting bridge comprises at least one of a polymer or a wax. (Item 21) 20. The method of claim 19, further comprising forming the connecting bridge into a curved shape to allow the first object region and the first support region to move relative to one another. (Item 22) 20. The method of claim 19, further comprising selectively heating and melting the bridge by applying an electric current. (Item 23) 20. The method of claim 19, further comprising dissolving the bridge with a solvent. (Item 24) 1. A system for additive manufacturing of an object, the system comprising: 1. An additive manufacturing device, comprising: depositing a first foil layer, the first foil layer comprising a first object region and a first support region connected to the first object region; depositing a second foil layer, the second foil layer comprising a second object region and a second support region; an additive manufacturing device configured to: an attachment mechanism configured to form an object section comprising the first object region and the second object region; and A system comprising: (Item 25) Item 25. The system of item 24, wherein the first support area and the second support area are configured to uniformly distribute at least one of temperature and pressure to the object segment. (Item 26) 25. The system of claim 24, wherein the additive manufacturing device is further configured to deposit a constraining material comprising carbon on at least one of the first foil layer or the second foil layer. (Item 27) 25. The system of claim 24, wherein the additive manufacturing device is further configured to deposit at least two additional foil layers between the first foil layer and the second foil layer. (Item 28) Item 25. The system of item 24, wherein the additive manufacturing device is configured to spot deposit the second foil layer onto the first foil layer. (Item 29) The attachment mechanism includes: attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support area to the first support area, the attached second support area and the first support area comprising a support section; Item 25. The system of item 24, further configured to: (Item 30) 30. The system of claim 29, wherein the first support segment is subdivided to facilitate piecewise removal from the object segment. (Item 31) Item 25. The system of item 24, further comprising a third support region connected to the first object region and a fourth support region connected to the second object region. (Item 32) The attachment mechanism includes: attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support area to the first support area, the attached second support area and the first support area comprising a first support section; attaching the third support region to the fourth support region, the attached third support region and the fourth support region comprising a second support section; Item 32. The system of item 31, further configured to: (Item 33) Item 33. The system of item 32, wherein the first support section and the second support section are configured to uniformly distribute temperature and pressure to the object through the first foil layer and the second foil layer. (Item 34) Item 33. The system of item 32, wherein the first support section and the second support section are configured to prevent deformation of the object section after initial deposition. (Item 35) Item 25. The system of item 24, wherein the first support region is connected to the first object region using a foil connecting bridge configured to increase the structural integrity of the first foil layer. (Item 36) Item 36. The system of item 35, wherein the foil connecting bridge is configured to be removed from the first object region. (Item 37) Item 25. The system of item 24, wherein the additive manufacturing device is further configured to deposit an inhibitor material on the first foil layer, the inhibitor material comprising at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon. (Item 38) 25. The system of claim 24, wherein the first foil layer and the second foil layer comprise aluminum. (Item 39) Item 25. The system of item 24, further comprising an alignment mechanism configured to align the second foil layer and the first foil layer by a first alignment feature in the first foil layer to a second alignment feature in the second foil layer. (Item 40) Item 40. The system of item 39, wherein the first alignment feature and the second alignment feature comprise at least one of a hole, a slot, or a tab pattern. (Item 41) Item 25. The system of item 24, wherein the first support region is connected to the first object region using a connecting bridge configured to increase the structural integrity of the first foil layer. (Item 42) Item 42. The system of item 41, wherein the connecting bridge comprises at least one of a polymer or a wax. (Item 43) Item 42. The system of item 41, wherein the connecting bridge is formed in a curved shape to allow the first object region and the first support region to move relative to each other. (Item 44) Item 42. The system of item 41, further comprising a device configured to apply an electric current to selectively heat and melt the bridge. (Item 45) Item 42. The system of item 41, further comprising a solvent applicator configured to apply a solvent to the bridge and dissolve the bridge using the solvent. [Brief explanation of the drawings]

[0052] Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following figures, in which like reference numerals refer to like parts throughout the various views unless otherwise specified.

[0053] [Figure 1] FIG. 1 depicts a cross-sectional side view of a manufactured metal laminate body according to one embodiment.

[0054] [Figure 2] FIG. 2 depicts an oblique view and an object view of the metal laminate object of FIG.

[0055] [Figure 3] FIG. 3 illustrates an alloy laminate article support according to one embodiment.

[0056] [Figure 4] FIG. 4 depicts a cross-sectional top view of a manufactured metal laminate body according to one embodiment.

[0057] [Figure 5] FIG. 5 depicts an oblique view and an object view of the metal laminate object of FIG.

[0058] [Figure 6] FIG. 6 depicts a top-down cross-sectional view of a metal laminate object fabricated with foil bridges in vertical restraint areas according to one embodiment.

[0059] [Figure 7] FIG. 7 depicts a cross-sectional view of a containment region between a support region and an object region in an individual foil layer according to one embodiment.

[0060] [Figure 8] FIG. 8 depicts a patterned and top-cut foil in a stack of foil sheets according to one embodiment.

[0061] [Figure 9] FIG. 9 depicts a pattern of cuts using the statistical bridging method according to one embodiment.

[0062] [Figure 10] FIG. 10 depicts the fracture of a bridge through thermal expansion according to one embodiment.

[0063] [Figure 11] FIG. 11 depicts a foil prepared using a wax bridge according to one embodiment.

[0064] [Figure 12] FIG. 12 depicts Joule heating employed to fracture bridges according to one embodiment.

[0065] [Figure 13] FIG. 13 depicts a foil sheet being treated with a solvent used to selectively dissolve the bridges according to one embodiment.

[0066] [Figure 14] FIG. 14 diagrammatically illustrates a method for additive manufacturing of an object according to one embodiment.

[0067] [Figure 15] FIG. 15 illustrates a system for additive manufacturing of an object according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0068] Various embodiments are described more fully below with reference to the accompanying drawings, which form a part of this specification and show specific exemplary embodiments. However, the concepts of the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as part of a thorough and complete disclosure to fully convey the scope of the concepts, techniques, and implementations of the present disclosure to those skilled in the art. The embodiments may be practiced as methods, systems, or devices. Thus, the embodiments may take the form of a hardware implementation, an entirely software implementation, or an implementation combining software and hardware aspects. Therefore, the following detailed description should not be taken in a limiting sense.

[0069] References in the specification to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one example implementation or technique according to this disclosure. Appearances of the phrase "in one embodiment" in various places in the specification do not necessarily all refer to the same embodiment.

[0070] Furthermore, the terminology used within the specification has been selected primarily for ease of reading and guidance purposes, and may not have been selected to precisely describe or delineate the boundaries of the disclosed subject matter. Thus, the present disclosure is intended to be illustrative and non-limiting with respect to the scope of the concepts discussed herein.

[0071] Embodiments described herein relate to methods and systems that enable the fabrication of complex geometries using metal LOM. In some embodiments, LOM bonds patterned sheets of foil together to form metal objects with strength comparable to machined objects. In some embodiments, the use of appropriate selective restraining support strategies allows objects with more complex geometries to be fabricated via LOM techniques as a global manufacturing strategy, so that object processing time and / or costs can be reduced.

[0072] In some embodiments, "selective inhibition" describes a strategy in which material is deposited, removed, or modified to prevent bonding in specific areas on any number of foil sheets comprising the object to be manufactured. In some embodiments, these patterned foils are configured to be stacked to simultaneously form the object and its support structure. In some embodiments, the system may use a bonding method to form strong metallurgical bonds in uninhibited locations between adjacent foil sheets. In some embodiments, the system may quench and homogenize the object to finish it. In some embodiments, the system may employ a removal technique to separate the object from its support structure. In some embodiments, a removal technique may be used at any point after the bonding step.

[0073] The terms "foil" and "foil layer" refer to constituent metal sheets that are stacked and bonded together to form an object and any supporting structure. In some embodiments, the foil has a thickness in one dimension of 10 μm to 10 mm. In some embodiments, the foil can be patterned in the other two dimensions to correspond to the design of the object and its supporting structure.

[0074] In some embodiments, a single foil layer may include at least one support region and at least one object region. "Support" refers to non-object components of the foil that, when joined together, form a holder or jig that conforms to the exterior of an object and can be used in subsequent post-processing. This holder or jig formed as a combination of multiple support regions may be referred to as a "support section." A combination of object regions may be referred to as an "object section."

[0075] "Bridge" refers to a connection of foil or another material.

[0076] There are two broad categories of selective inhabitation methods, distinguished by the plane in which the inhabitation is inhabited. The term "vertical inhabitation methods" refers to a group of methods that involve inhibi- tion of inhabitation at the boundary between the object and support regions within a single foil. A second category of inhabitation methods, called "horizontal inhabitation methods," encompasses inhabitation strategies at the inhabitation boundary between the object and support regions of two adjacent foils.

[0077] Embodiments of the vertical restraint method may include at least one of cutting the outline of the object region on a given foil layer using a laser, plasma cutter, drag knife, die cutter, milling, or other means. In some embodiments, the width of the cut in the vertical restraint region should be sufficient to prevent the object region from contacting the support region in a subsequent foil bonding step. In some embodiments, cutting the entire perimeter of the object region and completely separating it from the foil is not advantageous. In some embodiments, the presence of a bridge between the object region and the support region allows the foil to be handled prior to bonding, allowing complex geometries to be fabricated with greater reliability. In some embodiments, the bridge in the vertical restraint region may include an incomplete or interrupted cut that perforates the foil and leaves a small area of ​​foil between the object region and the support region. In some embodiments, the cut is made using a laser. The foil may be patterned in a way that creates a curved joint between the object section and the support section, which may facilitate removal of the object section after bonding. In some embodiments, the connecting bridge between the support region and the object region may be curved to allow the object region and the support region to move relative to one another.

[0078] In some embodiments, an additional material, such as wax, a polymer, a polymer blend, or a metal, can be added to the gap between the support and object regions of the foil to form a bridge between them. In some embodiments, one skilled in the art can select a bridge material that is solid at room temperature, has a melting point below the bonding temperature, does not chemically react with the foil, and decomposes into a liquid or vapor phase for ease of removal. In some embodiments, the method can include temporarily bonding the current layer of foil to the previous layer prior to the final foil bonding process, by laser spot welding, electrical spot welding, using an adhesive that will burn off cleanly during the final bond, or by mechanically deforming the current layer to interlock it with the previous layer.

[0079] In some embodiments, additional alignment features or patterns may be cut into each foil layer to aid in the alignment of subsequent foil layers. These features or patterns may be located in the object area, support area, or foil edge. In some embodiments, the alignment features in the support area may be holes and slots that may be located on two vertical pins. In some embodiments, subsequent foil layers may be stacked using the pins to maintain alignment between layers. In some embodiments, the alignment features on the foil layer edges may be cuts on the foil edge. In some embodiments, the foil layer may then be pressed against two or more machined or ground surfaces. In some embodiments, the system may apply either a slight preload from the side or a clamping force on top to keep the foil layers aligned during transport.

[0080] In some embodiments, small tab patterns may be cut and bent slightly out of plane within the foil layer. In some embodiments using tab patterns, when the tab patterns on the foil layers are configured to interlock with each other, external alignment features may not be required.

[0081] FIG. 1 depicts a cross-sectional side view of a manufactured metal laminate object 100 according to one embodiment. In some embodiments, the object 100 may be manufactured on a print base 105. In some embodiments, a foil layer 110 may be deposited onto the print base 105. The foil layer 110 may comprise at least one of an external support region 115, an internal support region 120, or an object region 125. In some embodiments, multiple foil layers may be either deposited directly onto the first foil layer 110 or added later onto the first foil layer 110. Each foil layer 110 may comprise at least one of the external support region 115, the internal support region 120, or the object region 125, respectively. As discussed in more detail below, the foil layer 110 may comprise at least one of a horizontal suppression region 130 or a vertical suppression region 135.

[0082] In some embodiments, the suppression areas 130, 135 may be formed at the intersection of the object area 125 and the support area 115 by cutting the foil layer 110 to form at least a portion of the vertical suppression area 135, or by blocking the top surface of the foil material of the current foil layer 110 to form at least a portion of the horizontal suppression area 130.

[0083] Figure 2 depicts an oblique view 205 and an object view 210 of the metal laminate object of Figure 1. The object is surrounded by support sections 215, 220, which may be removed after object section 225 is formed to complete the metal laminate object, as described in more detail below. In some embodiments, object section 225 may be offset upward from base 245 to ensure that the bonding and restraining process is consistent throughout object section 225.

[0084] For example, as shown in FIG. 3 , the object region 325 according to one embodiment can be deposited between two support regions 315 and 330. In some embodiments, the support regions 315, 330 can improve the strength of the laminated metal object body region 325 by creating a mold around the object to apply heat and pressure evenly during the bonding process. Similar to the water bath used in firing, a solid mold can help conduct heat and apply pressure more evenly than if heat and / or pressure were applied only directly to the object region 325 or to a print base (not shown). In some embodiments, the support regions 315, 330 can comprise scrap material from which similar objects have been fabricated. In some embodiments, the outer surfaces of the support regions 315, 330 can be flat. In some embodiments, the support regions 315, 330 can be configured to completely enclose the object region 325.

[0085] FIG. 4 depicts a top-down cross-sectional view of a fabricated metal laminate object 400 according to one embodiment. In some embodiments, each foil layer of object 400 may include an exterior support region 405, an interior support region 410, an object region 415, a vertical containment region 420, and a horizontal containment region 430. In some embodiments, support regions 405, 410 may be configured to be vertically divided and separate from object region 415. In some embodiments, large internal channel separation distances may be reduced to prevent support regions 405, 410 from becoming trapped. In some embodiments, object region 415 may include at least one small feature 450 that does not require support. In some embodiments, small feature 450 may be an internal cooling channel. As discussed in more detail below, some embodiments may include registration features, such as a pair of holes 460′, 460″, configured to allow alignment pins to be inserted during assembly of an object section including multiple object regions 415.

[0086] FIG. 5 depicts an oblique view 505 and an object view 510 of the metal laminate object of FIG. 4. In some embodiments, the support sections 535 can be split 525 vertically using a foil cutting tool (not shown), such as a laser, plasma cutter, drag knife, die cutter, milling, or other means. In some embodiments, this split allows for easier separation between the support sections 535 and the object sections 545. In some embodiments, the support sections 535 can be split into a grid-like pattern to facilitate easy support removal. In some embodiments, the support sections 535 can be spaced 2 mm to 100 mm apart, depending on the size and shape of the object 510. In some embodiments, the support sections 535 can be spaced farther apart if the object sections 545 have a parallel, flat shape. In some embodiments, the support sections 535 can be spaced closer together if the object sections 545 have a twisted or complex shape relative to the support sections 535.

[0087] FIG. 6 depicts a top-down cross-sectional view of a metal laminate object 600 according to one embodiment, fabricated with foil bridges 605 in the vertical restraint regions. In some embodiments, the metal is aluminum. Some embodiments may use bridges 605 to keep laminated metal object regions 610 aligned prior to bonding by weakly connecting object regions 610 to support regions 615, 620 within a layer, and may use a method to keep subsequent layers aligned by cutting alignment features 630′, 630″ (collectively, 630) into each layer 640. Some embodiments may align between 2 and 2,000 foil layers. Some embodiments may use a removable precision surface (not shown) to place alignment features 630, such as holes, prior to adding another foil layer. In some embodiments, the removable precision surface for placing alignment features 630 is a pin configured to be separated from object region 610 after bonding. In some embodiments, the removable precision surfaces can be aligned such that the foils are configured to be pressed against the surfaces before a preload is applied to lock them in place. In some embodiments, the alignment features 630 can be cut into at least one of the object region 610 or the support regions 615, 620.

[0088] In some embodiments, a foil bridge 605 between the object region 610 and the support regions 615, 620 is configured to increase the strength of the foil layer 640. In some embodiments, the increased strength allows the foil layer to be transported without removing the object region 610 from the support regions 615, 620. In some embodiments, the bridge 605 is formed by performing a perforation cut. In some embodiments, the bridge 605 is made from a different metal or alloy than the object region 610.

[0089] Some embodiments may use removal techniques associated with vertical restraint methods to detach or otherwise remove bridges 605 between support regions 615, 620 and object region 610. Vertical restraint methods may comprise physical break bridges 605, chemical break bridges 605, electrical break bridges 605, or any combination thereof.

[0090] In some embodiments of the vertical restraint method, the bridges 605 are physically broken and removed. In some embodiments, breaking the bridges allows a support section comprising multiple support regions 615, 620 to be detached and removed from an object comprising multiple object regions 610. In some embodiments, the bridges 605 can be broken after multiple foil layers 640 have been bonded together. The bridges 605 can be cut via the same methods used to cut individual foil layers 640, including lasers, plasma cutters, drag knives, die cutters, milling, or other physical means. In some embodiments, each bridge 605 can be cut multiple times to break the bridge into smaller pieces or powder. This allows the pieces to be easily removed using a vacuum or by forcing a gas or fluid through the assembly. For some geometries, it may be possible to puncture the bridges 605 with an awl or dilator pin (not shown).

[0091] In some embodiments, bridge 605 prevents puncture by allowing easy removal of the support section after stacking and attaching the foil layers.

[0092] 7 depicts a cross-sectional view of a suppression region between an object region 705 and a support region 710 within an individual foil layer according to one embodiment. In some embodiments, the object region 705 and the support region 710 have a width 715 sufficient to prevent the overlying foil from contacting the previously deposited layer 725. In some embodiments, when width 715 is wide enough, a horizontal suppression region is not needed.

[0093] In some embodiments, when the cut width is narrow, the containment region 735 can be formed on the previous layer such that the overlying foil does not contact the previous layer, and the containment region 735 is configured to prevent permanent bonding of the object region 750 of the subsequent layer with the support region 755 of the previous layer.

[0094] Methods for creating horizontal inhibition regions 735 include at least one of depositing an inhibition material and ablating the foil surface. Horizontal inhibition is successful when the inhibition material is stable at the bonding temperature and prevents the formation of a bond between the foils, or alternatively, in some embodiments, when the foils do not come into surface contact to form a bond.

[0095] In some embodiments, the inhibitor material is selectively deposited on the foil layer to create horizontal inhibitor regions 735. In some embodiments, the inhibitor material can be an oxide, ceramic, nitride, non-reactive salt, non-reactive metal, carbide, graphite, hydrocarbon, or other form of carbon. In some embodiments, the inhibitor material can be an oxidizer that reacts with the foil to form an oxide layer. In some embodiments, the inhibitor material can be deposited via various methods, including inkjet, marker, or glue extruder, or other deposition techniques whose equivalents would be recognizable to those skilled in the art. In some embodiments, metal oxides and ceramics can be suspended in a solution to aid deposition. In some embodiments, the deposition aid can include at least one of titanium oxide, aluminum oxide, zirconium oxide, carbide, boron nitride, titanium nitride, or carbon. In some embodiments, heat or a laser can be used to promote the formation of the oxide layer on the surface of the foil.

[0096] In some embodiments, horizontal restraints may be applied to the boundary between the object region 750 and the support region 755. In some embodiments, horizontal restraints may be applied to the support region 755 after every layer. In some embodiments, the layers may be divided horizontally every 3 to 500 layers, depending on the thickness of the foil layer 760. In some embodiments, the foil layer 760 may have a thickness of 100 μm to 500 μm. In some embodiments, the support spacing and horizontal restraint gap may be adjusted to prevent the object region 705 from mechanically interlocking with the support region 710.

[0097] In some embodiments of the horizontal restraint method, the surface of the foil is ablated using a laser, leaving a void between subsequent foil layers. The height of the void can be greater than the distance the metal expands during the bonding step to prevent contact between the two foils. In some embodiments, the oxidation of the surface caused by laser ablation will act as a bond restraint, similar to when metal oxide or other ceramic powders are deposited on the surface.

[0098] In some embodiments, the horizontal containment region 765 may not be present when the angle is steep enough that the overlying foil does not contact the previous layer, even if the cut width is narrow.

[0099] 8 depicts a patterned and top-cut foil in a stack of foil sheets 805 according to one embodiment. In some embodiments, the foil sheet 805 is patterned and cut so that the object region 810 is connected via bridges 820 to the remainder comprising the support region 815. In some embodiments, the foil sheet 805 may comprise a vertical containment region 840 to be removed. In some embodiments, this region 840 can be cut via an additional series of grid lines 845 to facilitate removal.

[0100] In some embodiments, grid lines 845 may be cut with consistent spacing around the perimeter of object region 810. In some embodiments, each support region 815 may be divided according to the size and shape of the object geometry to prevent support sections from interlocking. In some embodiments, both vertical cutting and horizontal restraint methods may be used to facilitate division and removal of support regions 815. In some embodiments, an additional layer of horizontal restraint may be applied to facilitate removal of objects stacked in the z-direction.

[0101] 9 depicts cutting a pattern using a statistical bridging method according to one embodiment. In some embodiments, an object pattern 905 on a foil 910 is cut via a laser or another tool that ablates portions of the foil according to some embodiments. The ablations may occur periodically along the object pattern 905 at a given frequency. The overlap between at least two of the ablations cuts through the entire thickness of the foil. In some embodiments, the cut depth may vary at different locations along the cut line 915, as shown in depth profile 920.

[0102] 10 depicts the fracturing of bridges through thermal expansion according to one embodiment. In some embodiments, a foil sheet 1005 is patterned into object regions 1010 and remaining support regions 1015 via cutting patterns 1020. In some embodiments, bridges 1025 connect object regions 1010 to the foil sheet 1005.

[0103] In some embodiments, the voids are formed by removing material of the pattern and filling the cutting zone 1030 with a second material with a larger coefficient of thermal expansion than the foil. In some embodiments, the second material may have a larger coefficient of thermal expansion than the support region. In some embodiments, the second material may not react with the object region or the support region.

[0104] Heat can then be conducted to or from the object and / or foil, causing thermal expansion 1035. In some embodiments, the expanded second material 1050 distorts the bridges 1045 until they fracture or are otherwise easily separable.

[0105] In some embodiments, material 1050 can be water or another material configured to expand when frozen. In some embodiments, cold air can be applied to or from the object and / or foil, causing the bridge to expand and fracture until the second material and object are easily separable. In some embodiments, the expansion can fracture the tabs, detaching support region 1015 from object region 1010.

[0106] In some embodiments, the bridge 1045 can be broken through thermal shock. In some embodiments, the bridge 1045 can be broken when the object is quenched following the bonding process. This method can be employed when the bridge 1045 has a different rate of thermal expansion than the object region 1010, such as when the bridge 1045 is formed using a different metal or metal alloy than the object region 1010.

[0107] FIG. 11 depicts a foil prepared using a wax bridge according to one embodiment. In some embodiments, a foil sheet 1105 is patterned and the object region 1110 and vertical restraint region 1115 are completely cut around their perimeter. In some embodiments, after cutting, wax is deposited to form a temporary bridge 1120 between the object region 1110 and the support region 1125. In some embodiments, the entire exterior surface of the object region 1110 can be completely separated from the support region 1125 using wax or polymer deposited to form the temporary bridge 1120 between the object region 1110 and the support region 1125. In some embodiments, this wax melts and pyrolyzes at a lower temperature than the object region 1110, allowing it to be removed when heat is applied. In some embodiments, heat can be applied during the bonding step.

[0108] In some embodiments, the bridge 1120 between the support region 1125 and the object region 1110 may include a modified material that may be more easily removed during the bonding step. For example, deposition of copper, zinc, silicon, or another alloy metal on the bridge 1120 would cause the bridge 1120 to have different material properties than the support region 1125 and the object region 1110. The composition of the bridge 1120, after deposition, may form a eutectic system that melts at a lower temperature than the support region 1125 and the object region 1110, and therefore may be melted and eliminated during the bonding step.

[0109] FIG. 12 depicts Joule heating employed to fracture bridges according to one embodiment. In some embodiments, a power system 1205 is placed in series with the object 1210. In some embodiments, current is applied across the bridge with electrodes contacting at points 1215 and 1220. In some embodiments of the vertical restraint method, current can be applied across the bridge between the object section and the support section. The applied current can be large enough to cause resistive heating that melts or deforms the support bridge and separates the object from the support body. In some embodiments, it can be used to fracture bridges or non-visible tabs.

[0110] 13 depicts a foil sheet being treated with a solvent used to selectively dissolve bridges according to one embodiment. In some embodiments, the foil sheet 1305 may be patterned with object regions 1310, and the foil sheet 1305 may have vertical restraint regions 1320 and remaining support regions 1315 established by undamaged bridges 1325.

[0111] In some embodiments, the gap areas formed inside the pattern may be partially or wholly filled with a corrosive solution 1330. In some embodiments, when solvent is applied to the foil sheet 1305, the bridges 1325 may begin to dissolve 1345. In some embodiments, if a sufficient amount of solvent is applied to the foil sheet 1305, the object areas 1360 may be completely severed 1355 from the support areas 1365 and the bridges may be completely dissolved.

[0112] In some embodiments of the vertical restraint method, the bridges 1325 can be selectively reacted, corroded, or otherwise dissolved by applying an alkaline solution to the surface. In some embodiments, a solution containing sodium hydroxide or potassium hydroxide preferentially dissolves the aluminum bridges 1325 because the bridges 1325 generally have a higher surface area per unit volume than the object regions 1310 and support regions 1315; therefore, the bridges 1325 will dissolve at a faster rate without significantly damaging the object regions and support regions. In some embodiments, the system can apply heat to increase the reaction rate for dissolving the bridges 1325.

[0113] In some embodiments, both vertical and horizontal constraint methods can be employed simultaneously in a single design, particularly for more complex 3D geometries, such as those requiring angled or curved surfaces that do not correspond to the vertical axis. Applying any combination of the above vertical and horizontal constraint methods requires the system to avoid interference with bridge placement with horizontal constraint sections that overlap bridges on adjacent foils. The number of bridges and the method employed to determine their placement depend on the constraint method, removal technique, object design features, and foil material properties. In some embodiments, the method can include thresholds for determining a minimum number of bridges per pattern feature or perimeter. In some embodiments, the method can include thresholds for determining when to generate horizontal constraint areas based on the object's overhang angle and / or cut width, and / or for placing horizontal constraint areas when adjacent foils would come into contact with support sections. In some embodiments, the method can have a lower area limit for generating horizontal constraint areas, assuming that horizontal constraint areas cannot be accurately formed below a certain area. In some embodiments, the method can involve offsetting the object upward from a base and generating support sections below it. In some embodiments, the offset may provide a precision platform for handling the object prior to final foil bonding, may ensure that the bonding and restraining process is consistent throughout the object, and / or may allow a less resistant print base to be used, both in terms of the flatness of the base and its absolute starting position.

[0114] FIG. 14 diagrammatically shows a method 1400 for additive manufacturing of an object, according to one embodiment. In some embodiments, the method includes depositing a first foil layer (step 1405). In some embodiments, the first foil layer may be deposited onto a print substrate. In some embodiments, the first foil layer may be deposited onto a foil layer. The first foil layer may comprise an object region and at least one support region connected to the object region. The first foil layer may comprise an object region and multiple support regions connected to the object region. In some embodiments, the method further includes depositing a second foil layer (step 1415). In some embodiments, the foil layer may be deposited using additive manufacturing. In some embodiments, a constraining layer may be deposited prior to depositing the second foil layer (step 1410). In some embodiments, the constraining layer may be deposited simultaneously with depositing the foil layer. In some embodiments, the containment layer may include at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon.

[0115] In some embodiments, the method includes aligning the foil layer (step 1420). In some embodiments, the layer may have alignment features in the support region or the object region. In some embodiments, the method includes aligning the alignment features, and by aligning the alignment features, the foil layer may be aligned. For example, in some embodiments, the alignment features may be at least one of holes, tabs, or slits, and the aligning may include provisionally passing a pin through the alignment feature to align the foil layer.

[0116] In some embodiments, the method includes forming an object in the foil layers (step 1425). In some embodiments, the object comprises object regions in the foil layers. In some embodiments, forming the object includes spot welding the foil layers together. In some embodiments, forming the object includes applying at least one of heat and pressure to the foil layers. In some embodiments, after the foil layers are aligned, the object regions in each foil layer are attached to the object regions in the other foil layers to form object segments. Additionally, at least some of the support regions in each foil layer are attached to at least some of the support regions in the other foil layers to form support segments. In some embodiments, the support segments are configured to uniformly distribute temperature and pressure to the object segments through the first and second foil layers. In some embodiments, the support segments are configured to prevent deformation of the object segments after initial deposition.

[0117] In some embodiments, the method further includes removing the support segments (step 1430). In some embodiments, the support segments may be subdivided to facilitate piecewise removal from the object. In some embodiments, the support segments may be removed by fracturing connecting bridges from the object.

[0118] 15 illustrates a system 1500 for additive manufacturing of an object according to one embodiment. In some embodiments, the system may include an additive manufacturing device 1505 configured to deposit a foil layer comprising an object region and a support region. In some embodiments, the device 1505 may deposit the foil layer onto a print substrate 1525. In some embodiments, the additive manufacturing device 1505 is configured to deposit a constraining material onto the foil layer comprising at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon. In some embodiments, the additive manufacturing device 1505 is configured to spot weld the foil layers together.

[0119] The system 1500 may include an attachment mechanism 1510 configured to form an object from an object region of the foil layer. The attachment mechanism 1510 may be configured to attach a support region of the foil layer. In some embodiments, the attachment mechanism 1510 may be configured to apply at least one of heat and pressure to the foil layer to form the object.

[0120] In some embodiments, the system 1500 may include a separator 1515 configured to facilitate removal of the support segments from the object. In some embodiments, the separator 1515 is configured to remove the support segments piecewise from the object.

[0121] In some embodiments, system 1500 may include an alignment mechanism 1520 configured to align registration features in the foil layer. In some embodiments, system 1500 may include a device 1530 configured to apply an electric current to selectively heat and melt the bridges. In some embodiments, system 1500 may include a solvent applicator 1535 configured to apply a solvent to the bridges and dissolve the bridges using the solvent.

[0122] The methods, systems, and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components, as appropriate. For example, in alternative configurations, methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Furthermore, features described for one configuration may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Furthermore, technology evolves, and thus many of the elements are examples and do not limit the scope of the disclosure or claims.

[0123] For example, embodiments of the present disclosure are described above with reference to block diagrams and / or operational illustrations of methods, systems, and computer program products according to embodiments of the present disclosure. The functions / acts noted in the blocks may occur out of the order shown in any flowchart. For example, two blocks shown in succession may in fact be executed substantially in parallel, and the blocks may sometimes be executed in reverse order, depending on the functionality / acts involved. Additionally or alternatively, not all of the blocks shown in any flowchart need be performed and / or executed. For example, if a given flowchart has five blocks containing functions / acts, it may be the case that only three of the five blocks are performed and / or executed. In this example, any three of the five blocks may be performed and / or executed.

[0124] A statement that a value exceeds (or exceeds) a first threshold is equivalent to a statement that the value meets or exceeds a second threshold that is slightly greater than the first threshold, e.g., the second threshold is a value that is higher than the first threshold within the resolution of the relevant system. A statement that a value is less than (or within) a first threshold is equivalent to a statement that the value is slightly less than the first threshold, less than or equal to a second threshold, e.g., the second threshold is a value that is lower than the first threshold within the resolution of the relevant system.

[0125] Specific details are given in the description to provide a thorough understanding of example configurations (including implementations). However, the configurations may be practiced without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques have been shown without unnecessary detail to avoid obscuring the configurations. This description provides only example configurations and does not limit the scope, applicability, or configuration of the claims. Rather, the foregoing description of the configurations will provide one skilled in the art with an enabling description for implementing the described techniques. Various changes may be made in the function and arrangement of elements without departing from the spirit or scope of the present disclosure.

Claims

1. 1. A method for additive manufacturing of an object, the method comprising: depositing a first foil layer, the first foil layer comprising a first object region and a first support region connected to the first object region; depositing a second foil layer, the second foil layer comprising a second object region and a second support region; forming an object segment comprising the first object region and the second object region; A method comprising:

2. The method of claim 1 , wherein the first and second support regions are configured to uniformly distribute at least one of temperature and pressure to the object segment.

3. The method of claim 1 , further comprising depositing a constraining material comprising carbon on at least one of the first foil layer or the second foil layer.

4. The method of claim 1 further comprising depositing at least two additional foil layers between the first foil layer and the second foil layer.

5. The method of claim 1 , wherein the second foil layer is spot welded onto the first foil layer.

6. attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support region to the first support region, the attached second support region and the first support region comprising a support section; The method of claim 1 further comprising:

7. The method of claim 6 , wherein the support segment is subdivided to facilitate piecewise removal from the object segment.

8. The method of claim 1 , further comprising a third support region connected to the first object region and a fourth support region connected to the second object region.

9. attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support region to the first support region, the attached second support region and the first support region comprising a first support section; 、 attaching the third support region to the fourth support region, the attached third support region and the fourth support region comprising a second support section; The method of claim 8 further comprising:

10. 10. The method of claim 9, wherein the first and second support sections are configured to uniformly distribute temperature and pressure to the object through the first and second foil layers.

11. The method of claim 9 , wherein the first support section and the second support section are configured to prevent deformation of the object section after initial deposition.

12. The method of claim 1 , wherein the first support region is connected to the first object region using a foil connecting bridge configured to increase the structural integrity of the first foil layer.

13. The method of claim 12 further comprising removing the foil connect bridge from the first object region.

14. 10. The method of claim 1, further comprising depositing a containment material on the first foil layer, the containment material comprising at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon.

15. The method of claim 1 , wherein the first foil layer and the second foil layer comprise aluminum.

16. 10. The method of claim 1, further comprising aligning the second foil layer and the first foil layer by a first registration feature in the first foil layer to a second registration feature in the second foil layer.

17. The method of claim 16 , wherein the first alignment feature and the second alignment feature comprise at least one of a hole, a slot, or a tab pattern.

18. The method of claim 1 , wherein the first foil layer and the second foil layer are deposited using additive manufacturing.

19. The method of claim 1 , wherein the first support region is connected to the first object region using a connecting bridge configured to increase the structural integrity of the first foil layer.

20. 20. The method of claim 19, wherein the connecting bridge comprises at least one of a polymer or a wax.

21. 20. The method of claim 19, further comprising forming the connecting bridge into a curved shape to allow the first object region and the first support region to move relative to one another.

22. 20. The method of claim 19, further comprising selectively heating and melting the connecting bridge by applying an electric current.

23. 20. The method of claim 19, further comprising dissolving the connecting bridge with a solvent.

24. 1. A system for additive manufacturing of an object, the system comprising:

1. An additive manufacturing device, comprising: depositing a first foil layer, the first foil layer comprising a first object region and a first support region connected to the first object region; depositing a second foil layer, the second foil layer comprising a second object region and a second support region; an additive manufacturing device configured to: an attachment mechanism configured to form an object section comprising the first object region and the second object region; A system comprising:

25. 25. The system of claim 24, wherein the first and second support regions are configured to uniformly distribute at least one of temperature and pressure to the object segment.

26. 25. The system of claim 24, wherein the additive manufacturing device is further configured to deposit a constraining material comprising carbon onto at least one of the first foil layer or the second foil layer.

27. 25. The system of claim 24, wherein the additive manufacturing device is further configured to deposit at least two additional foil layers between the first foil layer and the second foil layer.

28. 25. The system of claim 24, wherein the additive manufacturing device is configured to spot deposit the second foil layer onto the first foil layer.

29. The attachment mechanism includes: attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support region to the first support region, the attached second support region and the first support region comprising a support section; 25. The system of claim 24, further configured to:

30. 30. The system of claim 29, wherein the support segment is subdivided to facilitate piecewise removal from the object segment.

31. 25. The system of claim 24, further comprising a third support region connected to the first object region and a fourth support region connected to the second object region.

32. The attachment mechanism includes: attaching the second object region to the first object region, the attached second object region and the first object region comprising the object segment; attaching the second support region to the first support region, the attached second support region and the first support region comprising a first support section; attaching the third support region to the fourth support region, the attached third support region and the fourth support region comprising a second support section; 32. The system of claim 31, further configured to:

33. 33. The system of claim 32, wherein the first and second support segments are configured to uniformly distribute temperature and pressure to the object through the first and second foil layers.

34. 33. The system of claim 32, wherein the first support section and the second support section are configured to prevent deformation of the object section after initial deposition.

35. 25. The system of claim 24, wherein the first support region is connected to the first object region using a foil connecting bridge configured to increase the structural integrity of the first foil layer.

36. 36. The system of claim 35, wherein the foil connect bridge is configured to be removed from the first object region.

37. 25. The system of claim 24, wherein the additive manufacturing device is further configured to deposit a constraining material onto the first foil layer, the constraining material comprising at least one of an oxide, a ceramic, a nitride, a non-reactive salt, a non-reactive metal, a carbide, graphite, a hydrocarbon, or carbon.

38. 25. The system of claim 24, wherein the first foil layer and the second foil layer comprise aluminum.

39. 25. The system of claim 24, further comprising an alignment mechanism configured to align the second foil layer and the first foil layer by a first alignment feature in the first foil layer to a second alignment feature in the second foil layer.

40. 40. The system of claim 39, wherein the first alignment feature and the second alignment feature comprise at least one of a hole, a slot, or a tab pattern.

41. 25. The system of claim 24, wherein the first support region is connected to the first object region using a connecting bridge configured to increase the structural integrity of the first foil layer.

42. 42. The system of claim 41, wherein the connecting bridge comprises at least one of a polymer or a wax.

43. 42. The system of claim 41, wherein the connecting bridge is formed in a curved shape to allow the first object region and the first support region to move relative to one another.

44. 42. The system of claim 41, further comprising a device configured to apply an electric current to selectively heat and melt the connecting bridges.

45. 42. The system of claim 41, further comprising a solvent applicator configured to apply a solvent to the connecting bridge and dissolve the connecting bridge with the solvent.

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