Method and apparatus for fabrication of three-dimensional articl

Details Method and apparatus for fabrication of three-dimensional articl Method and apparatus for fabrication of three-dimensional articl

1990-12-03

1992-06-30

Evans, Geoffrey S.

Electric heating

Metal heating

By arc

118313, 118504, 118720, 118721, 164 46, 264308, 264317, 264221, B23K 2600, C23C 1604, B29C 3338, B22D 2300

Patent

active

051265290

ABSTRACT:
A method and apparatus for forming a three-dimensional object by thermal spraying utilizes a plurality of masks positioned and removed over a work surface in accordance with a predetermined sequence. The masks correspond to cross sections normal to a centerline through the workpiece. One set of masks defines all cross sections through the workpiece. A second set of masks contains at least one masks which corresponds to each mask of the first set. Masks from each set are alternatively placed above a work surface and sprayed with either a deposition material from which the workpiece will be made or a complementary material. In this manner, layers of material form a block of deposition material and complementary material. Then, the complementary material which serves as a support structure during forming is removed. Preferably, the complementary material has a lower melting temperature than the deposition material and is removed by heating the block. Alternatively, one could mask only for the deposition material and remove complementary material overlying the deposition material after each spraying of complementary material.

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