Additive Manufacturing using Kinetic MetallizationTM

Traditional metallic Additive Manufacturing (AM) processes employ metallic powder feedstock deposited as melted stereo lithographic layered structures. This technique frequently suffers from de-alloying due to loss of low melting point constituents. Further, properties are compromised due to rapid solidification rates in both the feedstock (powder) manufacture and in the SLS process itself. Additionally as the part grows heat soak back becomes a significant problem. Thus it would be desirable to manufacture parts from powder feedstock which eliminates laser or e-beam fusion. Moreover by shifting the paradigm to a non-traditional approach it should be possible to tune the mechanical properties to the needs of the component rather than the limitations of the process. The low temperature Kinetic Metallization^TMprocess provides a disruptive technology for attaining this objective. Using Direct Digital Manufacturing techniques coupled with the KM process this paper will explore methods for obtaining AM layups of multi-facet components with near net shape configurations and demonstrate the feasible of the technology for Additive Manufacturing.