Binder Jetting Transfer Platform Layering

The patent applies a release agent layer to the build plate before depositing the material layer. This preliminary action prevents adhesion between the green compact and build plate, enabling successful demolding of large-wall-thickness objects without compromising strength. The release agent is applied in advance to avoid residual stresses during demolding.

The patent extracts the release agent from the final component by using a removable build plate or by applying the release agent in a way that allows easy removal. This separates the demolding function from the final product, eliminating residual stresses that would otherwise remain in the component.

The patent uses a disposable or easily replaceable build plate that can be discarded or cleaned after each build. The build plate is designed to be consumed or replaced rather than permanently retained, eliminating the need to remove binder residues from the plate itself. This allows the use of binder jetting while avoiding contamination from plate residues.

The patent employs an inert or controlled atmosphere during the binder jetting process to prevent unwanted chemical reactions between the binder and the build plate or environment. This reduces the formation of harmful residues by creating a chemically inert processing environment.

The patent segments the sintering process into multiple stages with different temperature profiles and heating rates. This controlled segmentation allows gradual densification while minimizing thermal gradients and residual stresses. The process is divided into heating, holding, and cooling stages to maintain dimensional accuracy.

The patent modifies sintering parameters such as heating rate, holding time, and atmosphere composition to reduce shrinkage and residual stresses. By carefully controlling these parameters, the process achieves improved material properties while maintaining dimensional accuracy within acceptable tolerances.