Thermally decomposing build plate for facile release of 3d printed objects

Abstract

A method includes: obtaining a build plate useable in a 3D printing device, the build plate including a recessed section extending through a top surface of the build plate, and the recessed section including first and second sidewalls, and a lower surface extending from the first sidewall to the second sidewall; filling the recessed section with a liquid form of a metal or metal alloy; and cooling the metal or metal alloy below its solidus temperature such that the liquid form of the metal or metal alloy solidifies into a solid form of the metal or metal alloy. The solid form contacts the first sidewall, the second sidewall, and the lower surface. The solid form includes a build surface for forming a 3D printed metal object in the 3D printing device. The 3D printed metal object is releasable by melting the solid form of the metal or metal alloy.

What is claimed is: 
     
         1 . A method, comprising:
 obtaining a build plate useable in a 3D printing device, the build plate comprising:
 a top surface, a bottom surface, and sidewalls; and 
 a recessed section extending through the top surface and including a first sidewall, a second sidewall opposite the first sidewall, and a lower surface between the top and bottom surfaces, the lower surface extending from the first sidewall to the second sidewall; 
   filling the recessed section with a liquid form of a metal or metal alloy; and   cooling the metal or metal alloy below its solidus temperature such that the liquid form of the metal or metal alloy solidifies into a solid form of the metal or metal alloy that is in touching relation with the first sidewall, the second sidewall, and the lower surface, the solid form of the metal or metal alloy including a build surface for forming a 3D printed metal object in the 3D printing device, wherein the metal or metal alloy has a solidus temperature that is lower than a solidus temperature of the 3D printed metal object and lower than a solidus temperature of a material forming the top surface, the bottom surface, and the sidewalls of the build plate.   
     
     
         2 . The method of  claim 1 , wherein filling the recessed section with a liquid form of the metal or metal alloy comprises pouring the liquid form of the metal or metal alloy through a hole extending from the bottom surface of the build plate through the lower surface of the recessed section. 
     
     
         3 . The method of  claim 1 , further comprising: printing, using the 3D printing device, the 3D printed metal object onto the build surface of the solid form of the metal or metal alloy. 
     
     
         4 . The method of  claim 3 , further comprising: after printing the 3D printed metal object onto the build surface:
 melting the solid form of the metal or metal alloy by heating the metal or metal alloy above the solidus temperature of the metal or metal alloy; and   after melting the solid form of the metal or metal alloy, releasing the 3D printed metal object from the build plate.   
     
     
         5 . The method of  claim 4 , further comprising: after melting the solid form of the metal or metal alloy: removing the melted metal or metal alloy from the recessed section. 
     
     
         6 . The method of  claim 5 , wherein removing the melted metal or metal alloy from the recessed section comprises: draining the metal or metal alloy through a hole extending from the lower surface of the recessed section through the bottom surface of the build plate. 
     
     
         7 . The method of  claim 5 , further comprising: collecting, in a container, the melted metal or metal alloy removed from the recessed section. 
     
     
         8 . The method of  claim 5 , further comprising: after removing the melted metal or metal alloy from the recessed section:
 refiling the recessed section with a liquid form of a refill metal or metal alloy; and   cooling the refill metal or metal alloy below its solidus temperature such that the liquid form of the refill metal or metal alloy solidifies into a solid form of the refill metal or metal alloy.   
     
     
         9 . The method of  claim 8 , wherein the refill liquid metal or metal alloy comprises the metal or metal alloy removed from the recessed section. 
     
     
         10 . The method of  claim 1 , wherein the build surface of the solid form of the metal or metal alloy is flush to the top surface of the build plate. 
     
     
         11 . A method, comprising:
 obtaining a build plate assembly useable in a 3D printing device, the build plate assembly comprising:
 a top surface, a bottom surface, and sidewalls; 
 a recessed section formed through the top surface, the recessed section including a first sidewall, a second sidewall opposite the first sidewall, and a lower surface between the top and bottom surfaces, the lower surface extending from the first sidewall to the second sidewall; and 
 a solid form of a metal or metal alloy filling the recessed section such that it is in touching relation with the first sidewall, the second sidewall, and the lower surface, the solid form of the metal or metal alloy including a build surface; and 
   printing, using the 3D printing device, a 3D printed metal object onto the build surface of the solid form of the metal or metal alloy, wherein the metal or metal alloy has a solidus temperature that is lower than a solidus temperature of the 3D printed metal object and lower than a solidus temperature of a material forming the top surface, the bottom surface, and the sidewalls of the build plate.   
     
     
         12 . The method of  claim 11 , further comprising: after printing the 3D printed metal object onto the build surface:
 melting the solid form of the metal or metal alloy by heating the metal or metal alloy above the solidus temperature of the metal or metal alloy; and   after melting the solid form of the metal or metal alloy, releasing the 3D printed metal object from the build plate.   
     
     
         13 . The method of  claim 12 , further comprising: after melting the solid form of the metal or metal alloy: removing the melted metal or metal alloy from the recessed section. 
     
     
         14 . The method of  claim 13 , wherein removing the melted metal or metal alloy from the recessed section comprises: draining the metal or metal alloy through a hole extending from the lower surface of the recessed section through the bottom surface of the build plate. 
     
     
         15 . The method of  claim 13 , further comprising: after removing the melted metal or metal alloy from the recessed section:
 refiling the recessed section with a liquid form of a refill metal or metal alloy; and   cooling the refill metal or metal alloy below its solidus temperature such that the liquid form of the refill metal or metal alloy solidifies into a solid form of the refill metal or metal alloy.   
     
     
         16 . The method of  claim 11 , wherein the build surface of the solid form of the metal or metal alloy is flush to the top surface of the build plate. 
     
     
         17 . An additive manufacturing system, comprising:
 a build plate useable in a 3D printing device, the build plate comprising:
 a top surface, a bottom surface, and sidewalls; and 
 a recessed section extending through the top surface and including a first sidewall, a second sidewall opposite the first sidewall, and a lower surface between the top and bottom surfaces, the lower surface extending from the first sidewall to the second sidewall; and 
   a solid form of a metal or metal alloy filling the recessed section such that it is in touching relation with the first sidewall, the second sidewall, and the lower surface, the solid form of the metal or metal alloy including a build surface for forming a 3D printed metal object in the 3D printing device, wherein the metal or metal alloy has a solidus temperature that is lower than a solidus temperature of the 3D printed metal object and lower than a solidus temperature of a material forming the top surface, the bottom surface, and the sidewalls of the build plate.   
     
     
         18 . The additive manufacturing system of  claim 17 , wherein the solid form of the metal or metal alloy was formed by: filling the recessed section with a liquid form of the metal or metal alloy; and cooling the metal or metal alloy below its solidus temperature such that the liquid form of the metal or metal alloy solidified into the solid form. 
     
     
         19 . The additive manufacturing system of  claim 17 , further comprising:
 a 3D printing device; and   a powder of a second metal or metal alloy used to form the 3D printed metal object, the second metal or metal alloy having a solidus temperature that is higher than a solidus temperature of the metal or metal alloy.   
     
     
         20 . The additive manufacturing system of  claim 17 , wherein the build surface of the solid form of the metal or metal alloy is flat and flush at top edges of the recessed section of the build plate.