US 12,168,256 B2
Methods for fabricating metal articles by additive manufacturing
Haseung Chung, Ann Arbor, MI (US); and Patrick Kwon, Okemos, MI (US)
Assigned to BOARD OF TRUSTEES OF MICHIGAN STATE UNIVERSITY, East Lansing, MI (US)
Filed by BOARD OF TRUSTEES OF MICHIGAN STATE UNIVERSITY, East Lansing, MI (US)
Filed on Apr. 22, 2022, as Appl. No. 17/726,733.
Claims priority of provisional application 63/178,787, filed on Apr. 23, 2021.
Prior Publication US 2022/0339704 A1, Oct. 27, 2022
Int. Cl. B22F 10/12 (2021.01); B22F 10/73 (2021.01); B29C 64/165 (2017.01); B29C 64/314 (2017.01); B29C 64/357 (2017.01); B29K 505/00 (2006.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 40/10 (2020.01)
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
OG exemplary drawing
 
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.