3D Metal Printing Anti-Scatter Grid via Layered Binder
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Solution Overview
Problem
Current manufacturing techniques for three-dimensional anti-scatter devices are resource and time intensive, requiring expensive machines and precise alignment, and involve complex casting processes that are difficult to scale and align accurately.
Innovation Solution
A method for three-dimensional metal printing using powdered metal and a binder, where patterns are printed onto a printing area with the binder applied before, during, or after the metal application, allowing layers to be stacked and infiltrated to form a cohesive structure, eliminating the need for casting and alignment of separate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional casting techniques are used to manufacture anti-scatter devices, then the devices can be produced with high density metal composition, but the manufacturing process becomes resource and time intensive requiring expensive machines and precise alignment
Solution Approach 1:
The anti-scatter device is divided into multiple layers, with each layer being cast separately using individual molds. This segmentation allows for simplified manufacturing of each layer while maintaining overall device precision through controlled assembly of the layered structure
Solution Approach 2:
The manufacturing process transitions from attempting to create a single complex three-dimensional structure in one piece to building the device layer by layer in a sequential manner, effectively adding a temporal dimension to the manufacturing process that simplifies each individual step
2Shape
If traditional casting techniques with multiple molds are used, then complex three-dimensional shapes can be achieved, but the manufacturing time and resource requirements increase significantly
Solution Approach 1:
The complex three-dimensional anti-scatter device is segmented into multiple manageable layers that can be manufactured using standard casting processes, enabling parallel production and reducing overall manufacturing time while maintaining the desired complex shape
Solution Approach 2:
Multiple layers are prepared and pre-assembled in the correct sequence before final bonding, allowing for preliminary quality checks and adjustments to be made on individual layers without affecting the entire manufacturing process
3Manufacturing precision
If multiple casted layers are stacked and aligned to form the anti-scatter device, then the desired three-dimensional structure can be achieved, but precise alignment becomes difficult and time consuming
Solution Approach 1:
Alignment features and reference marks are incorporated into each layer during the casting process itself, creating a standardized interface that simplifies the alignment of subsequent layers and reduces the time and precision requirements for assembly
Solution Approach 2:
A bonding agent or adhesive layer is used as an intermediary between the metal layers during assembly, providing a tolerance buffer that accommodates minor misalignments and simplifies the alignment process while maintaining structural integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces manufacturing time and costs by enabling the direct formation of three-dimensional structures with precise alignment and uniform composition, improving the efficiency and quality of anti-scatter devices.
Implementation Method 1
a binder configured to bind particles of the first layer of powdered metal... applying a second binder to the printing area and applying a second layer of powdered metal onto the printing area... the second binder configured to bind particles of the second layer of powdered metal... infiltrating the first and second layers of powdered metal using a third binder
Data Source
AI summary
One or more metal printing techniques are described for generating a three-dimensional metal structure, such as a one-dimensional or two-dimensional anti-scatter grid. The techniques comprise applying a thin layer of powdered metal onto a printing area and using a binder (which is printed onto the printing area according to a specified pattern) to bind the powdered metal particles together. The acts of applying powdered metal and a binder may be repeated a plurality of times until a three-dimensional metal structure having a specified height is created. Moreover, in one embodiment, once the layering is complete, another binder is applied to the one or more layers to provide strength and/or support. While heat may be used in some embodiments to activate one or more of the applied binders the three-dimensional metal structure is generally not heated to a melting point of the powdered metal.