CPC B22F 10/12 (2021.01) [B22F 10/73 (2021.01); B29C 64/165 (2017.08); B29C 64/314 (2017.08); B29C 64/357 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 40/10 (2020.01); B22F 2304/10 (2013.01); B29K 2505/00 (2013.01)] | 20 Claims |
1. A method for forming a metal article by additive manufacturing, the method comprising:
providing a metal particle suspension comprising (i) a UV-curable polymeric resin liquid medium, (ii) metal particles distributed throughout the liquid medium, and (iii) optionally boron-containing particles selected from the group consisting of elemental boron particles, boron carbide particles, boron nitride particles, and combinations thereof; wherein: (A) a combined amount of the metal particles and any boron-containing particles present is at least 98 wt. % of total solid content in the metal particle suspension, and (B) when present, an amount of the boron-containing particles is at most 1 wt. % of total solid content in the metal particle suspension;
applying a first layer of the metal particle suspension into a reservoir;
exposing a selected portion of the first layer to UV radiation for a sufficient time to cure the UV-curable polymeric resin in the liquid medium of the selected portion of the first layer, thereby forming a cured first layer comprising a first solid polymer layer in the selected portion with the metal particles distributed throughout the first solid polymer layer;
applying a subsequent layer of the metal particle suspension into the reservoir and on a cured underlying layer;
exposing a selected portion of the subsequent layer to UV radiation for a sufficient time to cure the UV-curable polymeric resin in the liquid medium of the selected portion of the subsequent layer, thereby forming a cured subsequent layer comprising a subsequent solid polymer layer in the selected portion with the metal particles distributed throughout the subsequent solid polymer layer; and
repeating application and curing of a subsequent layer of the metal particle suspension a plurality of times to form a plurality of cured subsequent layers and subsequent solid polymer layers, thereby forming a green part comprising the solid polymer layers with the metal particles therein.
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