Additively Manufactured Permeable Structures with Spatial Control
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Solution Overview
Problem
Conventional porous membranes and filters have uniform or highly directional permeability, making it difficult to achieve spatial control of permeability, which is necessary for applications like fuel injection in scramjets, medical diagnostics, and microfluidics, where variable permeability and arbitrary geometries are required without complex manufacturing processes.
Innovation Solution
Additively manufactured structures with multiple regions of varying permeability, achieved through co-sintering and wall-pinning techniques, allowing for the creation of composite structures with distinct permeability levels in three dimensions, enabling arbitrary geometries and integrated manifolds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional porous membranes or frits are used, then uniform permeability is achieved, but spatial permeability control is lost
Solution Approach 1:
The patent applies local quality by creating regions with different pore sizes and permeability characteristics within a single structure. The additive manufacturing process enables different areas to have tailored pore structures (e.g., smaller pores in filtration zones, larger pores in flow distribution zones), allowing each region to be optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
The patent segments the structure into multiple regions with distinct permeability characteristics. By dividing the structure into zones with different pore sizes and connectivity, it achieves spatial permeability control without requiring multiple separate components or complex assembly processes.
2Adaptability or versatility
If multiple independent structures with varying permeability are assembled, then spatial permeability control is achieved, but device complexity increases
Solution Approach 1:
The patent merges multiple functional regions with different permeability requirements into a single monolithic structure fabricated by additive manufacturing. This eliminates the need to assemble multiple separate porous components, reducing manufacturing complexity while maintaining the ability to control permeability spatially through digital design.
3Shape
If conventional additive manufacturing is used, then arbitrary geometries are achieved, but feature size control is limited
Solution Approach 1:
The patent utilizes parameter changes in the additive manufacturing process to control pore size and permeability. By adjusting process parameters such as laser power, scan speed, layer thickness, and hatching patterns, the method achieves precise control over feature sizes and pore structures while maintaining the ability to create arbitrary geometries.
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
The approach allows for controlled fluid flow distribution and feature size control at a smaller scale than traditional additive manufacturing limits, enabling structures with variable permeability and arbitrary geometries, enhancing applications such as fuel injection and medical diagnostics by improving aerodynamic efficiency and stability of laminar flow.
Implementation Method 1
co-sintering and wall-pinning techniques, allowing for the creation of composite structures with distinct permeability levels
Data Source
AI summary
Some variations provide an additively manufactured article comprising a first region and a second region, wherein the first region is a solid region or a porous region, wherein the second region has a pore size larger than the first-region pore size, and wherein the first-region average permeability is lower than the second-region average permeability. Some variations provide a co-sintering method of making an architected material with regions having different permeabilities, in which different additive-manufacturing process parameters are applied to distinct regions of the structure. Other variations provide a wall-pinning method of making an architected material with regions having different permeabilities, in which additive-manufacturing process parameters are selected to sinter pinned feedstock powder between solid walls. Engineered structures with controlled permeability, integrated manifolds, and arbitrary geometries are disclosed, without the requirement of complex manufacturing. Many uses are described for the disclosed additively manufactured articles.