发明人：
ÅKLINT, THORBJÖRN | CARLSTRÖM, ELIS | JOHANDER, PER | STIERNSTEDT, JOHANNA
摘要：
Method for additive layer manufacturing of objects comprised of more than one material with free-form capability for all included materials. The method can for example be used for producing packaging for Microsystems where the ceramic acts as an insulator and the secondary material is used to produce electrical or optical 3D conductor lines or electrical or optical 3D vias. The fine powder used in this method enables it to be used for building components with small feature size and demand for high precision. Other intended uses for this method is to build small mechanical precision parts or grinding tools, dental objects or medical implants.
技术问题语段：
The patent text discusses the use of 3D printing to create objects and microsystems with complex structures. The technical problem addressed in the text is the need to directly fabricate microsystems with true 3D structures using layered manufacturing methods that can integrate several materials and build resistors, waveguides, and other components without the need for separate packaging.
技术功效语段：
The invention allows for the efficient production of objects made of powder-based materials (such as ceramic, glass, or metal) with the addition of secondary materials (such as ceramic, glass, or metal) that have their own freeform capabilities.
权利要求：
1. A method (11) for additive layer manufacturing of objects (1) comprised of more than one material with free-form capability for all included materials with the steps of: a) providing (12) a flat substrate as a platform forming a support (2) for building the object (1), b) hydrophobizing (13) selected parts of a flat substrate by applying a hydrophobic solution (3a, 3b), c) spreading (14) a water-based powder suspension (4a, 4b) comprised of particles with a size below 5 µm in a layer with a thickness below 50 µm, d) applying (15) a binder (5) to the parts of the powder layer that should be retained in the shaped powder body, e) applying (16) one or more secondary materials (6a) as powder suspensions or powder pastes to the gaps in the layer created by the hydrophobic repulsion of the water-based suspension, f) repeatedly (17) adding powder layers (4a, 4b, 4c), hydrophobic areas (3a, 3b), binders (5a, 5b, 5c) and secondary materials as above to build a powder body of the desired shape and size, g) rinsing (18) or clearing the object from loose powder, and h) performing thermal treatment (19) to remove the binder and sinter the powder object to a solid body.
2. Method according to claim 1 further comprising, between steps g) and h), a step of removing the object from the support (2).
3. Method according to claim 1 or 2, wherein gaps in the powder layers are selectively filled with a sacrificial material (6a) that leaves cavities or channels in the sintered object.
4. Method according to any one of the preceding claims, wherein the powder suspension is deposited in layers by a doctor blade, slot die or extrusion method, wherein the hydrophobic material and binder is deposited by inkjet printing, and the secondary materials are deposited by dispensing or inkjet printing.
5. Method according to any one of the preceding claims, wherein the hydrophobic material (3a, 3b) is a solution or dispersion of fluorocarbons or silicones.
6. Method according to any one of the preceding claims, wherein the powder suspension consists of a ceramic or a hard metal powder.
7. Method according to any one of the preceding claims, wherein additional functionally is added by including dielectric, resistive, semi-conductive, magnetic or other functional materials for sensors or actuators.
8. Method according to any one of claims 1 to 7, wherein the method is used to create structures with conducting and insulating materials to create packaging for Microsystems.
9. Method according to any one of claims 1 to 7, wherein the method is used to create implants or dental replacements.
10. Method according to any one of claims 1 to 7, wherein the method is used to create tools for grinding or cutting.
11. Method according to any one of claims 1 to 7, wherein the method is used to create mechanical precision parts.
12. Method according to any one of claims 1 to 7, wherein the method is used to create channels and cavities in a ceramic material with metalized surfaces (7) for use as wave guides for microwaves.
13. Method according to any one of claims 1 to 7, wherein the method is used to create channels and cavities in a ceramic material with metalized surfaces (7) for transport of fluid.
14. Method according to any one of claims 1 to 7, wherein the method is used to create optical waveguides.
15. The method according to claim 14, wherein the waveguides are created in or on top of a ceramic material.