Rapid additive sintering of materials using electric fields

Abstract

Rapid additive sintering of materials using electric fields includes a pair of electrodes including a first and second electrode, a power supply operatively connected to the pair of electrodes, and an area in between the pair of electrodes that holds a material. The first electrode is configured for flash sintering the material. The first electrode may be movable and may include a stylus. The material may include powder and may include any of metallic and ceramic material. Multiple layers of materials may be flash sintered by the first electrode. The first electrode may generate an electric field between the first electrode and the material causes the flash sintering. A nozzle may supply the material at variable speeds. The first electrode may be configured to move at variable speeds and in variable directions. The flash sintering may occur at an electric field between 10-50000 V/cm and an electric current between 0-30A.

What is claimed is: 
     
         1 . An apparatus comprising:
 a pair of electrodes comprising a first electrode and a second electrode;   a power supply operatively connected to said pair of electrodes; and   an area in between said pair of electrodes that holds a material,   wherein said first electrode is configured for flash sintering said material.   
     
     
         2 . The apparatus of  claim 1 , wherein said first electrode is movable. 
     
     
         3 . The apparatus of  claim 1 , wherein said first electrode comprises a stylus. 
     
     
         4 . The apparatus of  claim 1 , wherein said material comprises powder. 
     
     
         5 . The apparatus of  claim 1 , wherein said material comprises any of metallic and ceramic material. 
     
     
         6 . The apparatus of  claim 1 , further comprising multiple layers of materials flash sintered by said first electrode. 
     
     
         7 . The apparatus of  claim 1 , wherein said first electrode generates an electric field between said first electrode and said material causes said flash sintering. 
     
     
         8 . The apparatus of  claim 1 , further comprising a nozzle that supplies said material, wherein said nozzle is configured to supply said material at variable speeds. 
     
     
         9 . The apparatus of  claim 2 , wherein said first electrode is configured to move at variable speeds and in variable directions. 
     
     
         10 . The apparatus of  claim 7 , wherein said flash sintering occurs at an electric field between 10-50000 V/cm and an electric current between 0-30 A. 
     
     
         11 . A method comprising:
 positioning a pair of electrodes comprising a first electrode and a second electrode;   positioning material in between said pair of electrodes; and   applying an electric field between said first electrode and said material causing flash sintering of said material.   
     
     
         12 . The method of  claim 11 , further comprising moving said first electrode over said material. 
     
     
         13 . The method of  claim 11 , wherein said material comprises powder. 
     
     
         14 . The method of  claim 11 , wherein said material comprises any of metallic and ceramic material. 
     
     
         15 . The method of  claim 11 , further comprising:
 applying additional material after said flash sintering; and   performing another flash sintering process.   
     
     
         16 . The method of  claim 15 , further comprising forming multiple layers of sintered material. 
     
     
         17 . The method of  claim 16 , further comprising shaping said multiple layers into a three-dimensional (3D) structure. 
     
     
         18 . The method of  claim 11 , further comprising supplying said material at variable speeds. 
     
     
         19 . The method of  claim 12 , further comprising moving said first electrode at variable speeds and in variable directions. 
     
     
         20 . The method of  claim 12 , wherein said flash sintering occurs at an electric field between 10-50000 V/cm and an electric current between 0-30 A.