Markforged is a continuous innovation company. In 2016, Markforged launched Mark Two's next-generation product-Mark X 3D printer, which also integrates Markforged's continuous fiber filament (CFF) 3D printing technology. However, when this technology is used to print wire materials, there is a recognized pain point in the industry that is the control challenge of deformation and shrinkage.
Markforged applied for a patent to control the sintering deformation and shrinkage during the post-processing of 3D printing through binder and ceramic material 3D printing technology.
Better support and more accurate deformation control
The patent applied by Markforged is completed by printing the binder and ceramic material as the separation layer together with the support layer, so that the green body obtained by metal 3D printing has better prevention of deformation and heat shrinkage control.
Printing of three materials
Markforged received the published patent on February 11, 2020
Of course, the metal wire, adhesive, and ceramic material are printed by an independent extrusion head. In a typical printing process, the metal wire is melted and deposited on the platform. When the release layer is needed, the adhesive is 3D printed, and when the support layer is needed, the ceramic is printed layer by layer, thus forming a certain division and support for the metal part.
Degreasing and sintering
Followed by degreasing and sintering, during the sintering process, the green body always shrinks at a uniform rate, so that the entire shape remains controllable. After sintering, the release layer may become loose powder, and at the same time, the ceramic powder is loosened by sintering, and Finally, partly separated from the metal.
In the field of indirect metal 3D printing, Markforged's direct competitor is Desktop Metal. According to the market research of 3D Science Valley, Desktop Metal announced in early 2018 that it obtained the patent for the separable support technology, and this technology can achieve 3D printing and manufacturing of large and complex parts through metal sintering and manual removal of metal support structures.
In additive manufacturing, the geometric features of the manufactured products are often expanded by supporting structures, for example, by providing underlayer support for overhang structures to achieve more complex geometric structures.
However, when using support materials that require additional processing (such as the need for additional debonding and sintering to obtain the final part), conventional support strategies and techniques can lead to failure of parts processing, such as deformation of the support structure or When shrinking, it will affect the structure of the parts. At this time, a very matching strategy is required so that the supporting structure can not only play a supporting role in the processing process, but also does not affect the accuracy of the parts in the subsequent post-processing.
For Desktop Metal's equipment, the patent mentions an interface layer between the component and the support structure to suppress the bond between the support structure and the adjacent component surface during sintering.
This involves two materials, the first material is a binder system, including one or more binders. Helps maintain the net shape of the part during processing of the part into the final product, where the interface layer resists the bonding of the support structure to the part during sintering.
The second material includes powder metallurgy materials. The powder material may be metal powder or ceramic powder. Also includes metal infiltrant or ceramic infiltrant.
Better deformation and shrinkage control. Markforged and Desktop Metal's progress in materials will further promote the industrial revolution catalyzed by 3D printing.
The combination of 3D printers and production lines will usher in a new era: one day, there will be small factories that sprout like mushrooms. These small factories are closer to consumers like communities. The operation of the factory is managed by software, and parts can be printed on demand without needing MOQ requirements. The new ideas in this new era are not only changes in manufacturing methods and business models, but more importantly, they can design lighter, cheaper and more efficient parts than in the past.
Whether it is Markforged or Desktop Metal, the emergence of small factories that have sprung up, material technology is the core force.
Just as chips bring revolution to the IT world, a large number of single-function aggregations can form wisdom. Chips interconnect the world. Trillions of honeycomb-like chips are the hardware foundation of the entire world, and the software system built on it It is the network economy. The world we live in is full of interconnected chips, and the touch of the entire planet has never been so sensitive. If the rapid spread of the revolution brought by the chip to IT is likened to the revolution that indirect metal 3D printing technology will bring to the manufacturing industry, then the arrival of this revolution is ongoing.