System and method for additive metal manufacturing

Abstract

A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.

We claim: 
     
         1 . A method for forming a physical object from a virtual model comprising:
 disposing an interface layer on a build plate;   within a working volume:
 machining the interface layer; 
 fabricating an object precursor, comprising a geometry corresponding to the virtual model, on the interface layer, wherein fabricating the object precursor comprises iteratively:
 depositing a build material layer over the interface layer; and 
 machining the build material layer, wherein the interface layer retains the build material layer during build material machining; 
 
   releasing the physical object from the build plate; and   sintering the object precursor to form the physical object.   
     
     
         2 . The method of  claim 1 , wherein the interface layer comprises an adhesive. 
     
     
         3 . The method of  claim 2 , wherein the adhesive comprises at least one of graphite, boron nitride, titania, or silica. 
     
     
         4 . The method of  claim 1 , wherein the interface layer retains the build material layer during build material machining with a layer attachment force, generated between the interface layer and the build material layer, that exceeds a shear force generated during machining the build material layer. 
     
     
         5 . The method of  claim 1 , wherein machining the interface layer comprising planarizing the interface layer. 
     
     
         6 . The method of  claim 5 , wherein a level face of the interface layer defines a reference point for fabricating the object precursor with the geometry corresponding to the virtual model. 
     
     
         7 . The method of  claim 5 , further comprising:
 depositing a support material layer; and   machining the support material layer.   
     
     
         8 . The method of  claim 7 , wherein depositing the support material comprises depositing a raft of support material directly on the build plate. 
     
     
         9 . The method of  claim 1 , further comprising transferring the build plate, retaining the object precursor using the interface layer, from the working volume to a furnace, wherein the object precursor is sintered in the furnace. 
     
     
         10 . The method of  claim 1 , wherein releasing the physical object from the build plate comprises decomposing the interface layer.