WO2020112176A1

WO2020112176A1 - Systems and methods for additive manufacturing

Info

Publication number: WO2020112176A1
Application number: PCT/US2019/042733
Authority: WO
Inventors: Andreas Kulovits
Original assignee: Arconic Inc.
Priority date: 2018-11-29
Filing date: 2019-07-22
Publication date: 2020-06-04

Abstract

Additive manufacturing systems and methods include inductively heating a part produced using the systems and/or methods. The additive manufacturing system comprises a material deposition region and a first induction coil. The material deposition region is adapted to receive an electrically conducting build material and comprises a material deposition surface. The first induction coil surrounds the material deposition region and is adapted to heat a first portion of the electrically conducting build material in the material deposition region utilizing induction heating via a magnetic field.

Description

TITLE

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING

CROSS-REFERENCE

[0001] This application claims priority to U.S. Provisional Patent Application No.

62/772,971, which was filed on November 29, 2018. The contents of which is incorporated by reference into this specification.

FIELD OF USE

[0002] The present disclosure relates to systems and methods using induction heating in additive manufacturing. The present disclosure also relates to parts produced using the systems and/or methods according to the present disclosure.

BACKGROUND

[0003] Additively manufacturing articles is challenging, as there are various stresses acting upon the build plate and/or partial build throughout the process. Obtaining suitable physical properties in additively manufactured parts presents challenges.

SUMMARY

[0004] According to one aspect of the present disclosure, an additive manufacturing system is provided. The additive manufacturing system comprises a material deposition region and a first induction coil. The material deposition region is adapted to receive an electrically conducting build material and comprises a material deposition surface. The first induction coil surrounds the material deposition region and is adapted to heat a first portion of the electrically conducting build material in the material deposition region utilizing induction heating via a magnetic field.

[0005] According to another aspect of the present disclosure, an additive manufacturing method is provided. More specifically, a layer of electrically conducting build material is deposited in a material deposition region of an additive manufacturing apparatus. The layer may be deposited on a material deposition surface of the material deposition region and/or on at least a portion of a previously deposited layer within the material deposition region. A selected region of the layer is affixed together in the selected region. The depositing of a layer and the affixing at least a region of the layer is repeated as needed to provide an additively manufactured part utilizing an additive manufacturing process. A first portion of the additively manufactured part is selectively heated utilizing induction heating via a magnetic field during additive manufacturing of the additively manufactured part.

[0006] It is understood that the inventions disclosed and described in this specification are not limited to the aspects summarized in this Summary. The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of various non-limiting and non-exhaustive aspects according to this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The features and advantages of the examples, and the manner of attaining them, will become more apparent, and the examples will be better understood, by reference to the following description taken in conjunction with the accompanying drawings, wherein:

[0008] FIG. l is a schematic depiction of a front elevational view of a non-limiting embodiment of an additive manufacturing system comprising a first induction coil according to the present disclosure;

[0009] FIG. 2A is a schematic perspective view of non-limiting embodiment of a material deposition region and two induction coils according to the present disclosure;

[0010] FIG. 2B is a schematic cross-sectional view of the material deposition region and two induction coils of FIG. 2A;

[0011] FIG. 2C is a schematic cross-sectional view of the material deposition region and two induction coils of FIG. 2A cut through the second induction coil;

[0012] FIG. 3 A is a schematic perspective view of a non-limiting embodiment of a material deposition region and three induction coils according to the present disclosure;

[0013] FIG. 3B is a schematic cross-sectional view of the material deposition region and three induction coils of FIG. 3 A cut through the first induction coil;

[0014] FIG. 3C is a schematic cross-sectional view of the material deposition region and three induction coils of FIG. 3 A cut through the second induction coil; [0015] FIG. 3D is a schematic cross-sectional view of the material deposition region and three induction coils of FIG. 3 A cut through the third induction coil;

[0016] FIG. 4 is a schematic front-elevational view of a non-limiting embodiment of a material deposition region including stationary and moveable induction coils according to the present disclosure; and

[0017] FIG. 5 is a flow chart illustrating a non-limiting embodiment of an additive manufacturing method according to the present disclosure.

[0018] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate certain embodiments, in one form, and such exemplifications are not to be construed as limiting the scope of the appended claims in any manner.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0019] Various non-limiting embodiments are described and illustrated herein to provide an overall understanding of the structure, function, and use of the disclosed methods, systems, and parts. The various non-limiting embodiments described and illustrated herein are non limiting and non-exhaustive. Thus, the invention is not limited by the description of the various non-limiting and non-exhaustive embodiments disclosed herein. Rather, the invention is defined solely by the claims. The features and characteristics illustrated and/or described in connection with various non-limiting embodiments may be combined with the features and characteristics of other embodiments. Such modifications and variations are intended to be included within the scope of this specification. As such, the claims may be amended to recite any features or characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Further, Applicant reserves the right to amend the claims to affirmatively disclaim features or characteristics that may be present in the prior art. The various non-limiting embodiments disclosed and described in this specification can comprise, consist of, or consist essentially of the features and characteristics as variously described herein.

[0020] Any patent, publication, or other disclosure material identified herein is incorporated herein by reference in its entirety unless otherwise indicated but only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material expressly set forth in this specification. As such, and to the extent necessary, the express disclosure as set forth in this specification supersedes any conflicting material incorporated by reference herein. Any material, or portion thereof, that is said to be incorporated by reference into this specification, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicant reserves the right to amend this specification to expressly recite any subject matter, or portion thereof, incorporated by reference herein.

[0021] Any references herein to“various non-limiting embodiments,”“some embodiments,” “one embodiment,”“an embodiment,” or like phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases“in various non-limiting embodiments,” “in some embodiments,”“in one embodiment,”“in an embodiment,” or like phrases in the specification do not necessarily refer to the same embodiment. Furthermore, the particular described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features, structures, or characteristics of one or more other embodiments without limitation. Such modifications and variations are intended to be included within the scope of the present embodiments.

[0022] In this specification, unless otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term“about,” in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0023] Also, any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of“1 to 10” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein. Accordingly, Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

[0024] The grammatical articles“a,”“an,” and“the,” as used herein, are intended to include “at least one” or“one or more,” unless otherwise indicated, even if“at least one” or“one or more” is expressly used in certain instances. Thus, the foregoing grammatical articles are used herein to refer to one or more than one (i.e., to“at least one”) of the particular identified elements. Further, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.

[0025] As used herein,“additive manufacturing” means“a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies,” as defined in ASTM F2792-12a, entitled“Standard

Terminology for Additively Manufacturing Technologies.” Non-limiting examples of additive manufacturing processes useful in producing products from feedstocks include, for example, BJAM (binder jet additive manufacturing), DMLS (direct metal laser sintering), SLM (selective laser melting), SLS (selective laser sintering), and EBM (electron beam melting), among others.

[0026] As used herein,“powder” refers to a material comprising a plurality of particles. Powder may be used in a powder bed in an additive manufacturing system or process to produce a tailored alloy product via additive manufacturing. Powder, as used herein, may comprise a single material or a blend of two or more materials. In certain embodiments, powder can comprise shavings.

[0027] As used herein, a“median particle size” of a powder refers to the diameter at which 50% of the volume of the particles in the powder has a smaller diameter (e.g., Dso). Dio of a powder refers to the diameter at which 10% of the volume of the particles in the powder has a smaller diameter. D90 of a powder refers to the diameter at which 90% of the volume of the particles in the powder has a smaller diameter. As used herein, median particle size, Dio, and D90 are determined in accordance with ASTM standard B822. [0028] A part made by conventional additive manufacturing techniques may form cracks in the part. The present inventors observed that the cracks may be limited by heating the entire material deposition region of an additive manufacturing apparatus, including the build material and the part. However, as the present inventors observed, heating the entire build region may not be practical and may differentially heat areas of the part, resulting in different microstructures in different regions of the additively manufactured part. For example, the first layer of a part can be heated until the last layer is printed, and this may result in the first and last layer having different microstructures and different properties. Additionally, heating loose powder in the powder deposition region may degrade the loose powder in a manner that makes it unsuitable for recycling for further use in additively manufacturing parts. Thus, the present inventors provide herein embodiments of additive manufacturing systems comprising an induction coil and additive manufacturing methods utilizing induction heating. The resulting parts produced utilizing these systems and methods can have more consistent properties throughout, and loose powder remaining in the powder deposition region can be recycled for use in another build of an additively manufactured part.

[0029] Referring to FIG. 1, a schematic representation of a front-el evational view of a non limiting embodiment of an additive manufacturing system 100 according to the present disclosure is provided. The additive manufacturing system 100 can be adapted to conduct an additive manufacturing process, such as, for example, BJAM, DMLS, SLM, SLS, or EBM. The additive manufacturing system 100 can comprise a material deposition region 102 including a material deposition surface 104, a first induction coil 106, a material deposition module 108, and, optionally, a joining module 114. The material deposition region 102 is adapted to receive electrically conducting build material forming layers of an additively manufactured part.

[0030] The first induction coil 106 can surround the material deposition region 102. In various non-limiting embodiments, the first induction coil 106 can be disposed in an orientation substantially parallel to build layers 112a, 112b within the material deposition region 102. The first induction coil 106 can be adapted to heat electrically conducting build material in the material deposition region 102 utilizing induction heating via a magnetic field (e.g., radio frequency energy). The first induction coil 106 can induce a magnetic field surrounding and penetrating at least a portion of the electrically conducting build material in the material deposition region 102. The magnetic field can induce eddy-currents within and heat the electrically conducting build material. In various non-limiting embodiments, the magnetic field can cause hysteresis within and heat the electrically conducting build material. The first induction coil 106 can be various types of devices which generate a magnetic field suitable for heating the electrically conducting build material in the material deposition region 102. For example, the first induction coil 106 can comprise a power supply and a conductive coil in electrical communication with the power supply. The power supply can send an alternating current (AC) through the conductive coil, which induces a magnetic field. The parameters (e.g., frequency, current, voltage) of the AC current sent through the coil can affect the amount of heating and the penetration depth of the heating in the electrically conducting build material in the material deposition region 102.

[0031] The first induction coil 106 can be adapted to selectively heat a first portion 120 of the electrically conducting build material utilizing induction heating via a magnetic field. The first portion 120 may be heated to a first temperature that is greater than a temperature of electrically conducting build material that is not subjected to the induction heating. The size of the first portion 120 can be adjusted based on the configuration of the first induction coil 106. In various non-limiting embodiments, the first portion 120 can have a planar shape.

[0032] The first induction coil 106 can be moveable relative to the material deposition surface 104. The first induction coil 106 can be moved to adjust which portion of the electrically conducting build material in the material deposition region 102 can be inductively heated. For example, the first induction coil 106 can move in a first direction 126a and a second direction 126b to change the position of the first induction coil 106 relative to the material deposition surface 104.

[0033] The electrically conducting build material can comprise at least one of a metallic material, a polymeric material, and a ceramic material. The electrically conducting build material can be an electrical conductor or a semi-conductor. For example, the electrically conducting build material can comprise a composite material, such as, for example, both a conductor (e.g., a metallic material) and an insulator (e.g., a polymeric material and/or a ceramic material). The electrically conducting build material can comprise at least one of titanium, a titanium alloy, aluminum, an aluminum alloy, nickel, a nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, a gold alloy, platinum, a platinum alloy, zirconium, and a zirconium alloy. Regardless of the composition of the electrically conducting build material, the electrically conductive build material has a composition that can be inductively heated.

[0034] The electrically conducting build material can comprise powder, wire, and/or sheet.

In certain embodiments, where the electrically conducting build material is a powder, the electrically conducting build material can comprise at least one of metallic particles, polymer particles (e.g., plastic particles), and ceramic particles. In various non-limiting embodiments, each of the powders are metallic particles selected from at least one of titanium particles, titanium alloy particles, aluminum particles, aluminum alloy particles, nickel particles, nickel alloy particles, iron particles, iron alloy particles, cobalt particles, cobalt alloy particles, copper particles, copper alloy particles, molybdenum particles, molybdenum alloy particles, magnesium particles, magnesium alloy particles, tantalum particles, tantalum alloy particles, tungsten particles, tungsten alloy particles, zinc particles, zinc alloy particles, silver particles, silver alloy particles, chromium particles, chromium alloy particles, tin particles, tin alloy particles, gold particles, gold alloy particles, platinum particles, platinum alloy particles, zirconium particles, and zirconium alloy particles. In certain non-limiting embodiments, the ceramic particles can be at least one of oxide ceramic particles and non-oxide ceramic particles. In various non-limiting embodiments, the ceramic particles can comprise at least one of an oxide, a carbide, a nitride, and a boride.

[0035] The median particle size of the powder can be adapted for powder bed additive manufacturing. For example, the median particle size of the powder can be adapted so that the powder will spread in a uniform layer across the material deposition surface 104 or on a previously deposited layer in the material deposition region 102 In certain embodiments, the powder can include a median particle size not greater than 325 pm, such as, for example, not greater than 200 pm, not greater than 275 pm, not greater than 250 pm, not greater than 225 pm, not greater than 200 pm, not greater than 175 pm, not greater than 150 pm, not greater than 125 pm, not greater than 100 pm, not greater than 90 pm, not greater than 70 pm, not greater than 10 pm, not greater than 5 pm, or not greater than 1 pm. In certain embodiments, the powder can include a median particle size of at least 50 nm, such as, for example, at least 1 pm, at least 5 pm, at least 10 pm, at least 70 pm, at least 90 pm, at least 100 pm, at least 125 pm, at least 150 pm, at least 175 pm, at least 200 pm, at least 225 pm, at least 250 pm, at least 275 pm, or at least 300 pm. In certain embodiments, the powder can include a median particle size in a range of 50 nm to 325 pm, such as, for example, 1 pm to 300 pm, 5 pm to 300 pm, 5 pm to 100 pm, 10 pm to 180 pm, 100 pm to 180 pm, 10 pm to 100 pm,

105 pm to 180 pm, 20 pm to 50 pm, 60 pm to 90 pm, 50 pm to 100 pm, 10 pm to 50 pm, 10 pm to 80 pm, 10 pm to 20 pm, or 25 pm to 50 pm.

[0036] The median particle size of the powder can be compatible with the thickness of a layer formed from the powder in the material deposition region 102. For example, the layer thickness can be from 1 time to 10 times the median particle size of the powder in the layer, such as, for example, 2 to 8 times the median particle size, or 2 to 4 times the median particle size. In some embodiments, the layer thickness can be 3 times the median particle size. The layer thickness can be, for example, from 100 nm to 3,250 pm, such as, for example, 1 pm to 2,000 pm, 10 pm to 2,000 pm, 10 pm to 1,000 pm, or 50 pm to 300 pm. In various non limiting embodiments, the layer thickness can be 1,000 pm.

[0037] In various non-limiting embodiments, the material deposition module 108 can comprise at least one of a re-coater, a roller, a brush, a hopper, a conveyor, an extruder, and a reagent dispenser to facilitate deposition of build material layers 112a, 112b. In

embodiments without a joining module 114, the electrically conducting build material can be an extruder and a reagent dispenser. In various non-limiting embodiments, the system 100 can comprise an ultraviolet wavelength curing module to aid in curing of dispensed reagent. In various non-limiting embodiments, the material deposition module 108 can comprise a powder deposition module adapted to deposit layers of powder in the material deposition region 102. For example, the powder deposition module can comprise a re-coater which can spread powder in the material deposition region 102 from a reservoir. In various non-limiting embodiments comprising a powder deposition module, the powder can be initially deposited on the material deposition surface 104 and subsequently deposited on a powder layer or layers previously deposited in the material deposition region 102. In various non-limiting embodiments, the material deposition surface 104 is adapted to translate vertically to move the powder bed and facilitate deposition of further powder layers in the material deposition region 102.

[0038] The material deposition module 108 can move electrically conducting build material to the material deposition region 102 and deposit the first layer 112a in the material deposition region 102. The material deposition module 108 can deposit the second layer 112b in the material deposition region 102 on at least a region of the top surface of the first layer 112a. In various non-limiting embodiments, the material deposition module 108 can repeat the deposition of layers of electrically conductive build material as necessary to create layers of an additively manufactured part.

[0039] In embodiments comprising the joining module 114, at least a selected region 116 of the electrically conducting build material in first layer 112a in the material deposition region 102 can be affixed (e.g., bound and/or fused) together by the joining module 114. At least a selected region 118 of the electrically conducting build material in second layer 112b in the material deposition region 102 can be affixed together by the joining module 114. Affixing the electrically conducting build material in the selected region 118 can affix at least the selected region 118 of the second layer 112b to the first layer 112a. For example, the selected region 118 in the second layer 112b can be affixed to the selected region 116 in the first layer 112a. The bound selected regions 116, 118 can each form a build layer of the additively manufactured part.

[0040] Each electrically conducting build material layer in the part can be individually affixed by the joining module 114 or, alternatively, two or more layers can be affixed simultaneously. For example, the material deposition module 108 can deposit a single layer of electrically conducting build material or a plurality of layers of electrically conducting build material. Next, the joining module 114 can affix a selected region or regions in the material deposition region 102 including an exposed region. In various non-limiting embodiments, electrically conducting build material in at least a selected region 116 in the first layer 112a in the material deposition region 102 can be affixed together by the joining module 114 prior to deposition of the electrically conducting material forming the second layer 112b. In various non-limiting embodiments, electrically conducting material in at least the selected region 116 in the first layer 112a and the selected region 118 in the second layer 112b are affixed simultaneously. In various non-limiting embodiments, the joining module 114 can affix the first layer 112a at least partially to the material deposition surface 104.

[0041] The joining module 114 can be at least one of a binder deposition module and an energy source. The binder deposition module can be adapted to deposit a binder on a selected region of an exposed layer of electrically conducting build material in the material deposition region 102 to bind the electrically conducting build material in the selected region of the layer together and to electrically conducting build material in an immediately adjacent underlying layer or to an underlying region of the (e.g., of electrically conducting build material, previously affixed electrically conducting build material, material deposition surface 104). For example, the selected region 118 in the second layer 112b can be affixed to the selected region 116 in the first layer 112a by the binder applied by the joining module 114. In various non-limiting embodiments, the binder can be a liquid binder.

[0042] In embodiments in which the joining module 114 is an energy source, the source can be adapted to selectively sinter and/or melt electrically conducting build material in a selected region of an exposed layer of electrically conducting build material in the material deposition region 102 to fuse the electrically conducting build material in the selected region of the layer together and to an immediately adjacent underlying layer. For example, the selected region 118 in the second layer 112b can be fused to the selected region 116 in the first layer 112a by the energy source. The energy source can comprise, for example, at least one of a laser module, an electron beam module, and a plasma torch module. A laser module can be adapted to direct a laser beam onto and heat at least a selected region of an exposed layer of electrically conducting build material in the material deposition region 102 to fuse the electrically conducting build material in the selected region together and to an immediately adjacent underlying layer. An electron beam module can be adapted to direct an electron beam onto and heat at least a selected region of an exposed layer of electrically conducting build material in the material reposition region 102 to fuse electrically conducting build material in the selected region together and to an immediately adjacent underlying layer. A plasma torch module can be adapted to direct plasma onto and heat at least a selected region of an exposed layer of electrically conducting build material in the material deposition region 102 to fuse the electrically conducting build material in the selected region together and to an immediately adjacent underlying layer. For example, the selected region 118 in the second layer 112b can be fused to the selected region 116 in the first layer 112a by the laser module, electron beam module, or plasma torch module. In various non-limiting embodiments, the energy source can be adapted to selectively sinter and/or melt electrically conducting build material in a selected region of an exposed layer of electrically conducting build material in the material deposition region 102 to fuse the electrically conducting build material in the selected region of the layer together and to at least two underlying layers, including an immediately adjacent underlying layer and an additional layer of electrically conducting build material underlying the immediately adjacent underlying layer. [0043] The sequence of depositing a layer or layers of electrically conducting build material and affixing a selected region or regions of the layer or layers can be repeated as needed to produce layers of the additively manufactured part, which includes electrically conducting build material bound/fused together.

[0044] FIGs. 2A-C illustrate aspects of an additive manufacturing apparatus including material deposition region 202 and two induction coils according to the present disclosure.

As illustrated, a first induction coil 106 from FIG. 1 and a second induction coil 206 are disposed surrounding the material deposition region 202. In various non-limiting

embodiments, the second induction coil 206 can be disposed substantially perpendicular to the first induction coil 106. In various non-limiting embodiments, the first induction coil 106 can be disposed in an orientation substantially parallel to the build layers 212a-j of electrically conducting build material within the material deposition region 202.

[0045] The first and second induction coils 106, 206, can selectively heat the electrically conducting build material 228 within the material deposition region 202. The second induction coil 206 can be adapted to heat a second portion 220 of the electrically conducting build material 228 in the material deposition region 202 utilizing induction heating via a magnetic field. The second portion 220 can be heated to a second temperature by the second induction coil 206. The second temperature may be the same as or different than the first temperature of the first portion 120. The first portion 120 and the second portion 220 can intersect within the material deposition region 202 and create a first zone 224. The first zone 224 can be heated to a third temperature by the combined heating action of the first and second induction coils 106, 206. The third temperature is greater than the first temperature and the second temperature. The first temperature and the second temperature can be greater than a temperature of the electrically conducting build material 228 within the material deposition region 202 that is not subjected to induction heating via a magnetic field. The size of the second portion 220 can be adjusted based on the configuration of the second induction coil 206. In various non-limiting embodiments, the second portion 220 can have a planar shape.

[0046] The first and second induction coils 106, 206 can be moveable relative to the material deposition surface 202. The movement of the first and second induction coils 106, 206 can be used to adjust which portion of the electrically conducting build material in the material deposition region 202 can be selectively heated. The second induction coil 206 can be moveable relative to the material deposition region 202 in a third direction 226a and a fourth direction 226b to change the location of the second induction coil 206 relative to the material deposition region 204. The movement of the first and second induction coils 106, 206 can move the first and second portions 120, 220, respectively, and, thus, the first zone 224.

[0047] FIGs. 3A-D illustrate aspects of an additive manufacturing system including a material deposition region 302 and three induction coils according to the present disclosure. As illustrated, the first induction coil 106 from FIG. 1, the second induction coil 206 from FIGs. 2A-C, and a third induction coil 306 can be disposed surrounding the material deposition region 302 and electrically conducting build material 328 therein. In various non limiting embodiments, the third induction coil 306 can be disposed substantially

perpendicular to the first induction coil 106. In various non-limiting embodiments, the third induction coil 306 can be disposed substantially perpendicular to the second induction coil 206. In various non-limiting embodiments, the third induction coil 306 may not be substantially perpendicular to the first induction coil 106. In various non-limiting embodiments, the third induction coil 306 may be at an angle of 45 degrees relative to the first induction coil 106. The positions and orientations of the first, second, and third induction coils 106, 206, and 306 relative to each other and the material deposition region 302 described and depicted herein should not be considered limiting.

[0048] The third induction coil 306 can be adapted to heat a third portion 320 of the electrically conducting build material 328 utilizing induction heating via a magnetic field. The third portion 320 may be heated to a fourth temperature by the third induction coil 306. The fourth temperature may be the same as or different than the first temperature, the second temperature, and/or the third temperature. The third portion 320 and the second portion 220 can intersect within the material deposition region 302 and create a second zone 332. The second zone 332 can be heated to a fifth temperature by the combined heating action of both the second and third induction coils 206, 306. The third portion 320 and the first portion 120 can intersect within the material deposition region 202 and create a third zone 334. The third zone 334 can be heated to a sixth temperature by both the first and second induction coils 106, 206. The first portion 120, the second portion 220, and the third portion 320 can intersect within the material deposition region 202 and create a fourth zone 336. The fourth zone 336 can be heated to a seventh temperature by the combined heating action of the first, second, and third induction coils 106, 206, and 306. The seventh temperature can be greater than the first, second, third, fourth, fifth, and sixth temperatures. In various non-limiting embodiments, the third portion 320 can comprise a planar shape.

[0049] The size of the first, second, and third portions 120, 220, 320 can be adjusted based on the configuration of the first, second, and third induction coils 106, 206, 306, respectively.

The movement of the first, second, and third induction coils 106, 206, 306 can be used to adjust which portion of the electrically conducting build material 328 in the material deposition region 302 is heated.

[0050] The first, second, and third induction coils 106, 206, 306 can be moveable relative to the material deposition surface 302. The movement of the first, second, and third induction coils 106, 206, 306 can be used to adjust which portion of the electrically conducting build material in the material deposition region 302 can be selectively heated. The third induction coil 306 can be moveable relative to the material deposition surface 302 in a fifth direction 326a and a sixth direction 326b. The movement of the first, second, and third induction coils 106, 206, 306 can move the first, second, and third portions 120, 220, and 320, respectively, and, thus, the first, second, third, and fourth zones 224, 332, 334, and 336.

[0051] Referring to FIG. 4, a schematic view of a material deposition region 402 of an additive manufacturing system including stationary and moveable induction coils according to the present disclosure is provided. As illustrated, a moveable induction coil 406 can be disposed surrounding the material deposition region 402 including electrically conducting build material 428. The moveable induction coil 406 can be adapted to heat a portion 420 of the electrically conducting build material 428. The portion 420 can comprise less than one of the layers 412a-j, the same amount as one of the layers 412a-j, or more than one of layers 412a-j. For example, as illustrated, the portion 420 can comprise a part of layer 412d and all of layer 412e and layer 412f.

[0052] A first induction coil member 438a can be disposed surrounding the material deposition region 402. In various non-limiting embodiments, a second induction coil member 438b, a second induction coil member 438c, and a fourth induction coil member 438d can be provided. The induction coil members 438a-d can be stationary. In order to heat the electrically conducting build material, the induction coil members 438a-d can be selectively activated to induce a magnetic field and heat a portion of the electrically conducting build material. For example, the first induction coil member 438a can be activated to heat layers 412a-c; the second induction coil member 438b can be activated to heat layers 412c-e; the third induction coil member 438c can be activated to heat layers 412f- h; and the fourth induction coil member 438d can be activated heat layers 412h-j. The induction coil members 438a-d can be activated together or independently. The amount of electrically conducting build material 428 each induction coil member 438a-d can heat should not be considered limiting.

[0053] A stationary induction coil 440 can be adapted to heat all of the electrically conducting build material 428. The stationary induction coil 440 can ensure that all of the electrically conducting build material 428 can be at least partially heated. In various non limiting embodiments, the stationary induction coil 440 can control an environmental temperature within an additive manufacturing system.

[0054] FIG. 5 is a flow chart 500 illustrating a non-limiting embodiment of a process for producing a part by additive manufacturing according to the present disclosure. As indicated, a layer of electrically conducting build material is deposited on a material deposition surface of a material deposition region (502). Build material in a selected region of the layer is affixed together (504). A first portion of the additively manufactured part can be selectively heated utilizing induction heating via a magnetic field during additive manufacturing of the additively manufactured part (506). The first portion can be inductively heated to a first temperature. In various non-limiting embodiments, the magnetic field can be moved to a position adapted to heat another portion of the additively manufactured part.

[0055] In various non-limiting embodiments, a second portion of the additively manufactured part can be selectively heated utilizing induction heating via a magnetic field during additive manufacturing of the additively manufactured part (508). The second portion can be inductively heated to a second temperature. A first zone comprising an intersection of the first portion with the second portion can be created in the material deposition region (510). The first zone can be inductively heated to a third temperature greater than the first temperature and the second temperature.

[0056] In various non-limiting embodiments, a third portion of the additively manufactured part can be heated utilizing induction heating via a magnetic field during additive

manufacturing of the additively manufactured part (512). The third portion can be inductively heated to a fourth temperature. In various non-limiting embodiments, a second zone comprising an intersection of the third portion with the second portion can be created in the material deposition region. The second zone can be inductively heated to a fifth temperature. In various non-limiting embodiments, a third zone comprising an intersection of the third portion with the first portion can be created in the material deposition region. The third zone can be inductively heated to a sixth temperature.

[0057] A fourth zone comprising an intersection of the first portion with the second portion and the third portion can be created in the material deposition region (514). The fourth zone can be inductively heated to a seventh temperature greater than the first, second, third, fourth, fifth, and sixth temperatures. In various non-limiting embodiments, the fourth zone can be selectively moved throughout the material deposition region as needed in order to selectively heat the electrically conducting build material.

[0058] The depositing of a layer and the affixing at least a region of the layer is repeated as needed (516) to provide an additively manufactured part utilizing an additive manufacturing process (518). In various non-limiting embodiments, the selective heating of at least one of the first, second, and third portions may be repeated as needed to provide an additively manufactured part utilizing an additive manufacturing process.

[0059] Additive Manufacturing

[0060] Any appropriate additive manufacturing technique described in ASTM F2792.-12a may be modified to include the inventive features described herein. In one embodiment, an additive manufacturing process includes depositing successive layers of powder and then selectively melting and/or sintering the powder to create, layer-by-layer, an additively manufactured part. The additive manufacturing process is modified to utilize one or more of the inventive features described herein. In one embodiment, inventive features described herein are used in conjunction with a powder bed to create a part, such as, for example, a tailored alloy part and/or a unique structure unachievable through traditional manufacturing techniques (e.g., without excessive post-processing machining).

[0061] Non-limiting examples of additive manufacturing processes useful in producing additively manufactured parts from feedstocks include, for example, BJAM, DMLS, SLM, SLS, and EBM, among others. In one embodiment, an additive manufacturing process uses an EOSINT M 280 Direct Metal Laser Sintering (DMLS) additive manufacturing system, or comparable system, available from EOS GmbH (Robert-Stirling-Ring 1, 82152

Krailling/Munich, Germany). Additive manufacturing techniques (e.g., when utilizing metallic feedstocks) may facilitate the selective heating of powder above the liquidus temperature of the powder, thereby forming a molten pool followed by rapid solidification of the molten pool.

[0062] Any suitable feedstocks may be used, including powder, a wire, a sheet, and combinations thereof. In various non-limiting embodiments, the feedstock may be, for example, metallic feedstocks (e.g., with additives to promote various properties, such as, for example, grain refiners and/or ceramic materials), polymeric feedstocks (e.g., plastic feedstocks), and ceramic feedstocks. In certain embodiments, the wire can comprise a ribbon and/or a tube. The metallic feedstocks can be or comprise at least one of titanium, a titanium alloy, aluminum, an aluminum alloy, nickel, a nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, gold alloy, platinum, platinum alloy, zirconium, and zirconium alloy. In certain embodiments, reagent-based feedstock materials which form polymeric parts can be used as feedstock.

[0063] As used herein,“aluminum alloy” means a metal alloy having aluminum as the predominant alloying element. Similar definitions apply to the other metal alloys referenced herein (e.g., titanium alloy means a metal alloy having titanium as the predominant alloying element).

[0064] In one approach, an additive manufacturing process comprises (a) dispersing a feedstock in a material deposition region (e.g., powder in a powder bed), (b) selectively heating a portion of the powder (e.g., via an energy source) to a temperature above the liquidus temperature of the powder, (c) forming a molten pool, and (d) cooling the molten pool at a cooling rate of at least 1000°C per second, such as, for example, at least 10,000°C per second, at least 100,000°C per second, or at least 1,000,000°C per second. Steps (a)-(d) may be repeated as necessary until the additively manufactured part is completed.

[0065] In another approach, an additive manufacturing process comprises (a) dispersing a feedstock (e.g., metallic powder) in a material deposition region, (b) selectively binder jetting the feedstock, and (c) repeating steps (a)-(b), thereby producing a final additively

manufactured part (e.g., including optionally heating to burn off binder and form a green form, followed by sintering to form the additively manufactured part). [0066] In another approach, electron beam or plasma arc techniques are utilized to produce at least a portion of the additively manufactured part. Electron beam techniques may facilitate production of larger parts than readily produced via laser additive manufacturing techniques. An illustrative example provides feeding a wire to a wire feeder component of an electron beam gun. The wire may comprise a metallic feedstock. The electron beam heats the wire above the liquidus point of the metallic feedstock and deposits the molten pool in a deposition region. Thereafter, the molten pool rapidly solidifies to form a portion of an additively manufactured part.

[0067] Production and Processing

[0068] In certain embodiments, the additively manufactured part may be subject to any appropriate dissolving (e.g., homogenization), working, and/or precipitation hardening steps. If employed, the dissolving and/or the working steps may be conducted on an intermediate form of the additively manufactured part and/or may be conducted on a final form of the additively manufactured part. If employed, the precipitation hardening step is generally conducted relative to the final form of the additively manufactured part.

[0069] After or during production, an additively manufactured part may be deformed (e.g., by one or more of rolling, extruding, forging, stretching, compressing). The final deformed product may have, for instance, improved properties due to the tailored regions and thermo mechanical processing of the final deformed part. Thus, in some embodiments, the final part is a wrought part, the word“wrought” referring to the working (hot working and/or cold working) of the additively manufactured part, wherein the working occurs to provide an intermediate and/or final form of the additively manufactured part. In other approaches, the final part is a non-wrought product, i.e., is not worked during or after the additive

manufacturing process. In these non-wrought product embodiments, any appropriate number of dissolving and precipitating steps may still be utilized.

[0070] Product Applications

[0071] The resulting additively manufactured parts made in accordance with the systems and methods described herein may be used in a variety of product applications such as commercial end-uses in industrial applications, in consumer applications (e.g., consumer electronics and/or appliances), or in other areas. For example, the additively manufactured parts can be utilized in at least one of the aerospace field (e.g., an aerospace component), automotive field (e.g., an automotive component), transportation field (e.g., a transportation component), or building and construction field (e.g., a building component or construction component). In certain embodiments, the additively manufactured parts can be configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component.

[0072] In one embodiment, an additively manufactured part can be utilized in an elevated temperature application, such as in an aerospace or automotive vehicle. In one embodiment, an additively manufactured part can be utilized as an engine component in an aerospace vehicle (e.g., in the form of a blade, such as a compressor blade incorporated into the engine). In another embodiment, an additively manufactured part can be used as a heat exchanger for the engine of the aerospace vehicle. The aerospace vehicle including the engine

component/heat exchanger may subsequently be operated. In one embodiment, an additively manufactured part can be an automotive engine component. The automotive vehicle including an automotive component (e.g., engine component) may subsequently be operated. For instance, the additively manufactured part may be used as a turbocharger component (e.g., a compressor wheel of a turbocharger, where elevated temperatures may be realized due to recycling engine exhaust back through the turbocharger), and the automotive vehicle including the turbocharger component may be operated. In another embodiment, an additively manufactured part may be used as a blade in a land based (stationary) turbine for electrical power generation, and the land-based turbine included the additively manufactured part may be operated to generate electrical power. In certain embodiments, an additively manufactured part can be utilized in defense applications, such as in body armor or in armored vehicles (e.g., armor plating). In other embodiments, the additively manufactured part can be utilized in consumer electronic applications, such as in consumer electronics such as laptop computer cases, battery cases, cell phones, cameras, mobile music players, handheld devices, computers, televisions, microwaves, cookware, washers/dryers, refrigerators, and sporting goods, among others.

[0073] In another aspect, an additively manufactured part can be utilized in a structural application, such as, for example, an aerospace structural application or an automotive structural application. For instance, the additively manufactured part may be formed into various aerospace structural components, including floor beams, seat rails, fuselage framing, bulkheads, spars, ribs, longerons, and brackets, among others. In another embodiment, the additively manufactured part can be utilized in an automotive structural application. For instance, the additively manufactured part can be formed into various automotive structural components including nodes of space frames, shock towers, and subframes, among others. In one embodiment, the additively manufactured part can be a body -in-white automotive product.

[0074] In another aspect, the additively manufactured part can be utilized in an industrial engineering application. For instance, the additively manufactured part or products may be formed into various industrial engineering products, such as tread-plate, tool boxes, bolting decks, bridge decks, and ramps, among others.

[0075] Various aspects of the invention according to the present disclosure include, but are not limited to, the aspects listed in the following numbered clauses.

1. An additive manufacturing system comprising:

a material deposition region adapted to receive an electrically conducting build material, the material deposition region comprising a material deposition surface; and

a first induction coil surrounding the material deposition region, the first induction coil adapted to heat a first portion of the electrically conducting build material in the material deposition region utilizing induction heating via a magnetic field.

2. The system of clause 1, further comprising:

at least two induction coils including a first induction coil and a second induction coil, the second induction coil surrounding the material deposition region, the second induction coil adapted to heat a second portion of the electrically conducting build material in the material deposition region utilizing induction heating via a magnetic field.

3. The system of clause 2, wherein the second induction coil is disposed substantially perpendicular to the first induction coil.

4. The system of any one of clauses 2-3, further comprising a first zone disposed in the material deposition region, the first zone comprising an intersection of the first portion with the second portion. 5. The system of clause 4, wherein the second induction coil is disposed substantially perpendicular to the first induction coil.

6. The system of any one of clauses 2-5, further comprising a third induction coil surrounding the material deposition region, the third induction coil adapted to heat a third portion of the electrically conducting build material utilizing induction heating via a magnetic field.

7. The system of claim 6, wherein the third induction coil is disposed substantially perpendicular to the first induction coil.

8. The system of any one of clauses 6-7, further comprising a second zone disposed in the material deposition region, the second zone comprising an intersection of the first portion with the second portion and the third portion.

9. The system of clause 8, wherein the third induction coil is disposed substantially perpendicular to the first induction coil and the second induction coil.

10. The system of any one of clauses 6-9, wherein at least one of the first induction coil, the second induction coil, and the third induction coil is moveable relative to the material deposition surface.

11. The system of any one of clauses 6-10, wherein at least one of the first portion, the second portion, and the third portion has a planar shape.

12. The system of any one of clauses 1-11, wherein the electrically conducting build material is a powder and the system further comprises:

a powder deposition module adapted to dispose the powder on the material deposition surface; and

a joining module adapted to affix at least a selected region of the powder.

13. The system of clause 12, wherein the joining module comprises at least one of a binder deposition module and an energy source. 14. The system of any one of clauses 1-13, wherein the electrically conducting build material comprises powder having a median particle size in a range of 50 nm to 325 pm.

15. The system of any one of clauses 1-14, wherein the electrically conducting build material comprises at least one of metallic particles, polymer particles, and ceramic particles.

16. The system of any one of clauses 1-15, wherein the electrically conducting build material is a conductor or semi-conductor.

17. The system of any one of clauses 1-16, wherein the electrically conducting build material comprises at least one of titanium, a titanium alloy, aluminum, an aluminum alloy, nickel, a nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, a gold alloy, platinum, a platinum alloy, zirconium, and a zirconium alloy.

18. The system of any one of clauses 1-17, wherein the additive manufacturing system is adapted to conduct an additive manufacturing process selected from at least one of binder jet additive manufacturing, electron beam melting, direct metal laser sintering, selective laser melting, and selective laser sintering.

19. An additive manufacturing method comprising:

depositing a layer of electrically conducting build material in a material deposition region of an additive manufacturing system;

affixing together electrically conductive build material in a selected region of the layer;

repeating the depositing of a layer and the affixing together as needed to provide an additively manufactured part utilizing an additive manufacturing process; and

selectively heating a first portion of the additively manufactured part utilizing induction heating via a magnetic field during additive manufacturing of the additively manufactured part.

20. The method of clause 19, further comprising: selectively heating a second portion of the additively manufactured part utilizing induction heating via a magnetic field during additive manufacturing of the additively manufactured part.

21. The method of clause 20, wherein the second portion is substantially perpendicular to the first portion.

22. The method of any one of clauses 20-21, further comprising:

creating a first zone disposed in the material deposition region, the first zone comprising an intersection of the first portion with the second portion.

23. The method of clause 22, wherein the first portion is substantially perpendicular to the second portion.

24. The method of any one of clauses 20-23, further comprising:

selectively heating a third portion of the additively manufactured part utilizing induction heating via a magnetic field during additive manufacturing of the additively manufactured part.

25. The method of clause 24, wherein the third portion is substantially perpendicular to the first portion.

26. The method of any one of clauses 24-25, further comprising:

creating a second zone disposed in the material deposition region, the second zone comprising an intersection of the first portion with the second portion and the third portion.

27. The method of clause 26, wherein the first portion is substantially perpendicular to the second portion and the third portion.

28. The method of any one of clauses 19-27, further comprising:

moving the magnetic field to a position adapted to heat a second portion of the additively manufactured part. 29. The method of any one of clauses 19-28, wherein the electrically conducting build material comprises at least one of metallic particles, polymer particles, and ceramic particles.

30. The method of any one of clauses 19-29, wherein the electrically conducting build material is a conductor or semi-conductor.

31. The method of any one of clauses 19-30, wherein the electrically conducting build material comprises at least one of titanium, a titanium alloy, aluminum, an aluminum alloy, nickel, a nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, a gold alloy, platinum, a platinum alloy, zirconium, and a zirconium alloy.

32. The method of any one of clauses 19-31, wherein the electrically conducting build material comprises powder having a median particle size in a range of 50 nm to 325 pm.

33. The method of any one of clauses 19-32, wherein the additive manufacturing process is at least one of binder jet additive manufacturing, electron beam melting, direct metal laser sintering, selective laser melting, and selective laser sintering.

34. The method of any one of clauses 19-33, wherein the additively manufactured part is configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component.

[0076] One skilled in the art will recognize that the herein described methods, processes, systems, apparatus, components, devices, operations/actions, and objects, and the discussion accompanying them, are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific examples/embodiments set forth and the accompanying discussion are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components, devices, operations/actions, and objects should not be taken as limiting. While the present disclosure provides descriptions of various specific aspects for the purpose of illustrating various aspects of the present disclosure and/or its potential applications, it is understood that variations and modifications will occur to those skilled in the art. Accordingly, the invention or inventions described herein should be understood to be at least as broad as they are claimed and not as more narrowly defined by particular illustrative aspects provided herein.

Claims

CLAIMS What is claimed is:

1. An additive manufacturing system comprising:

2. The system of claim 1, further comprising:

3. The system of claim 2, wherein the second induction coil is disposed substantially perpendicular to the first induction coil.

4. The system of any one of claims 2-3, further comprising a first zone disposed in the material deposition region, the first zone comprising an intersection of the first portion with the second portion.

5. The system of claim 4, wherein the second induction coil is disposed substantially perpendicular to the first induction coil.

6. The system of any one of claims 2-5, further comprising a third induction coil surrounding the material deposition region, the third induction coil adapted to heat a third portion of the electrically conducting build material utilizing induction heating via a magnetic field.

8. The system of any one of claims 6-7, further comprising a second zone disposed in the material deposition region, the second zone comprising an intersection of the first portion with the second portion and the third portion.

9. The system of claim 8, wherein the third induction coil is disposed substantially perpendicular to the first induction coil and the second induction coil.

10. The system of any one of claims 6-9, wherein at least one of the first induction coil, the second induction coil, and the third induction coil is moveable relative to the material deposition surface.

11. The system of any one of claims 6-10, wherein at least one of the first portion, the second portion, and the third portion has a planar shape.

12. The system of any one of claims 1-11, wherein the electrically conducting build material is a powder and the system further comprises:

a joining module adapted to affix at least a selected region of the powder.

13. The system of claim 12, wherein the joining module comprises at least one of a binder deposition module and an energy source.

14. The system of any one of claims 1-13, wherein the electrically conducting build material comprises powder having a median particle size in a range of 50 nm to 325 pm.

15. The system of any one of claims 1-14, wherein the electrically conducting build material comprises at least one of metallic particles, polymer particles, and ceramic particles.

16. The system of any one of claims 1-15, wherein the electrically conducting build materials is a conductor or semi-conductor.

17. The system of any one of claims 1-16, wherein the electrically conducting build material comprises at least one of titanium, a titanium alloy, aluminum, an aluminum alloy, nickel, a nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, a gold alloy, platinum, a platinum alloy, zirconium, and a zirconium alloy.

18. The system of any one of claims 1-17, wherein the additive manufacturing system is adapted to conduct at least one of binder jet additive manufacturing, electron beam melting, direct metal laser sintering, selective laser melting, and selective laser sintering.

19. An additive manufacturing method comprising:

depositing a layer of electrically conducting build material on a material deposition surface of a material deposition region;

affixing a selected region of the layer together in the selected region;

repeating the depositing of a layer and the affixing at least a region of the layer as needed to provide an additively manufactured part utilizing an additive manufacturing process; and

20. The method of claim 19, further comprising:

selectively heating a second portion of the additively manufactured part utilizing induction heating via a magnetic field during additive manufacturing of the additively manufactured part.

21. The method of claim 20, wherein the second portion is substantially perpendicular to the first portion.

22. The method of any one of claims 20-21, further comprising: creating a first zone disposed in the material deposition region, the first zone comprising an intersection of the first portion with the second portion.

23. The method of claim 22, wherein the first portion is substantially perpendicular to the second portion.

24. The method of any one of claims 20-23, further comprising:

25. The method of claim 24, wherein the third portion is substantially perpendicular to the first portion.

26. The method of any one of claims 24-25, further comprising:

27. The method of claim 26, wherein the first portion is substantially perpendicular to the second portion and the third portion.

28. The method of any one of claims 19-27, further comprising:

moving the magnetic field to a position adapted to heat a second portion of the additively manufactured part.

29. The method of any one of claims 19-28, wherein the electrically conducting build material comprises at least one of metallic particles, polymer particles, and ceramic particles.

30. The method of any one of claims 19-29, wherein the electrically conducting build materials is a conductor or semi-conductor.

31. The method of any one of claims 19-30, wherein the electrically conducting build material comprises at least one of titanium, a titanium alloy, aluminum, aluminum alloy, nickel, nickel alloy, iron, an iron alloy, cobalt, a cobalt alloy, copper, a copper alloy, molybdenum, a molybdenum alloy, magnesium, a magnesium alloy, tantalum, a tantalum alloy, tungsten, a tungsten alloy, zinc, a zinc alloy, silver, a silver alloy, chromium, a chromium alloy, tin, a tin alloy, gold, a gold alloy, platinum, a platinum alloy, zirconium, and a zirconium alloy.

32. The method of any one of claims 19-31, wherein the electrically conducting build material comprises powder having a median particle size in a range of 50 nm to 325 pm.

33. The method of any one of claims 19-32, wherein the additive manufacturing process is at least one additive manufacturing process selected from binder jet additive

manufacturing, electron beam melting, direct metal laser sintering, selective laser melting, and selective laser sintering.

34. The method of any one of claims 19-33, wherein the additively manufactured part is configured as at least one of an aerospace component, an automotive component, a transportation component, and a building and construction component.