3D Printed Voxel Tailoring via Localized Heat Treatment
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Solution Overview
Problem
Conventional additive manufacturing (AM) processes for forming three-dimensional articles face complexity due to multiple heat, mass, and momentum transfer modes, leading to challenges in achieving localized control over properties such as transition temperatures, tensile strengths, and mechanical properties in materials like shape memory alloys.
Innovation Solution
The process involves locally tailoring voxels and portions of three-dimensional articles by adjusting energy beam parameters like power, exposure time, and secondary heat treatment below the melting point to manipulate microstructure and properties, allowing for varied properties within the same article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing processes are used to form three-dimensional articles, then the articles can be produced with complex geometries, but the processes face complexity due to multiple heat, mass, and momentum transfer modes, leading to challenges in achieving localized control over properties
Solution Approach 1:
The patent applies local quality by selectively applying secondary heat treatment to specific voxels or portions of the three-dimensional article after additive manufacturing. This allows different regions of the same article to have different thermal histories and resulting properties (such as transition temperatures, tensile strengths, and mechanical properties) without requiring complex process control during the main manufacturing operation. The energy beam parameters (power, exposure time, velocity) are locally adjusted to achieve the desired property variations in specific regions.
Solution Approach 2:
The patent employs preliminary action by performing secondary heat treatment as a post-processing step after the additive manufacturing process has created the base article. This preliminary characterization allows the complex thermal processing to be applied after the geometric structure is already formed, simplifying the overall process control while still achieving localized property tailoring through selective re-heating of specific regions.
2Adaptability or versatility
If energy beam parameters are adjusted to locally tailor voxels and portions, then varied properties can be achieved within the same article, but the process requires precise control of power, exposure time, and velocity
Solution Approach 1:
The patent implements parameter changes by systematically varying energy beam parameters (power, exposure time, velocity, hatch spacing) during the additive manufacturing and secondary heat treatment processes. These parameter changes enable the creation of different thermal profiles in different regions of the article, resulting in varied local properties such as different transition temperatures and mechanical strengths. The control system adjusts these parameters based on the desired property outcomes for specific voxels or portions.
3Manufacturing precision
If secondary heat treatment is applied below melting point to manipulate microstructure, then transition temperatures and mechanical properties can be tailored, but the process time increases
Solution Approach 1:
The patent applies segmentation by dividing the three-dimensional article into discrete voxels or portions that receive different secondary heat treatment conditions. This segmentation allows the heat treatment process to be applied selectively to only those regions requiring property modification, rather than treating the entire article uniformly. The energy beam scans through specific regions with adjusted parameters, reducing the overall process time compared to full-article treatment while still achieving the desired property tailoring in critical areas.
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 approach enables the creation of three-dimensional articles with tailored properties, such as different transition temperatures and mechanical strengths, without altering alloy compositions, enhancing the functionality and application range of AM-produced parts.
Implementation Method 1
thermally exposing a selected voxel and/or portion of the three-dimensional article with an energy beam at a temperature less than a melting point of the three-dimensional article
Implementation Method 2
a typical feedstock is a powdered metal composition of one or more metals that is sintered or fully melted by the energy input of a laser or electron beam, and as a result, is transformed layer by layer into a solid three-dimensional part
Implementation Method 3
The AM process uses an energy source, such as a laser or electron beam, to melt, fuse and/or consolidate a layer of material
Implementation Method 4
rapid heating above the melting temperature of the respective metal due to energy absorption from the laser (or electron beam) and its subsequent transformation into heat to form a molten metal followed by rapid solidification after the heat source has moved on
Data Source
AI summary
Additive manufacturing processes, systems and three-dimensional articles include the formation of voxels and/or portions of three-dimensional articles with different properties relative to other voxels and/or portions. The processes generally include changing one or more laser beam parameters including power level, exposure time, hatch spacing, point distance, velocity, and energy density during the formation of selected voxels and/or portions of the three-dimensional articles. Also disclosed are processes that include an additive manufacturing process that provides localized secondary heat treatment of certain voxels and/or regions at a temperature below the melting point of the three-dimensional article but high enough to effect a localized property change.