Additive Manufacturing Monolithic Reference Materials

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Solution Overview

Problem

Existing methods for synthesizing solid reference materials, such as those used by NIST, struggle to homogeneously distribute platinum group elements (PGEs) due to the formation of metallic nuggets, leading to a lack of reference materials for calibrating in situ measurements of PGEs in silicate matrices.

Innovation Solution

The method involves using analyte-doped particles, such as Stöber particles or metal oxides, as feedstock in an additive manufacturing process, specifically electrophoretic deposition (EPD), to create monolithic reference materials without the need for melting, thereby preventing the formation of metallic nuggets and achieving homogeneous distribution of PGEs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional synthesis methods are used to create solid reference materials, then the materials can be produced in bulk, but the platinum group elements form metallic nuggets leading to poor homogeneity

Engineering Contradiction:

Improvehomogeneity of PGE distributionVSAvoidcomplexity of synthesis process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The invention segments the PGE distribution problem by using individual doped particles as building blocks. Each particle is doped with PGEs during synthesis, ensuring homogeneous distribution at the particle level. These particles are then additively manufactured into a monolithic reference material, maintaining the homogeneous distribution throughout the bulk material without forming metallic nuggets.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies preliminary action by doping particles with PGEs before the final reference material synthesis. The particles are pre-synthesized with uniform PGE distribution incorporated into their structure. This preliminary doping prevents PGE segregation and metallic nugget formation during subsequent reference material manufacturing.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If existing silicate glass standards are used for calibration, then they provide a established reference system, but they exhibit significant spatial heterogeneity in element distribution

Engineering Contradiction:

Improveaccuracy of calibrationVSAvoidspatial homogeneity of elements

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention achieves homogeneity by incorporating PGEs into individual particles during their synthesis, ensuring uniform distribution at the particle level. When these homogeneous particles are additively manufactured into a monolithic structure, the homogeneous distribution is maintained throughout the entire reference material, eliminating the spatial heterogeneity present in conventional silicate glass standards.

Inventive Principle:

Principle #33Homogeneity

3Quantity of substance

If melting processes are used to synthesize reference materials, then bulk materials can be formed, but metallic nuggets form causing inhomogeneous PGE distribution

Engineering Contradiction:

Improvebulk material productionVSAvoidhomogeneity of PGE distribution

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The invention replaces the thermal melting process with an additive manufacturing approach. Instead of melting and cooling bulk materials where PGEs segregate into metallic nuggets, the invention uses doped particles as feedstock for additive manufacturing. This mechanical assembly process maintains homogeneous PGE distribution throughout the bulk material without requiring high-temperature melting.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 production of highly homogeneous reference materials with tunable chemical and isotopic compositions, suitable for calibrating microanalytical tools like LA-ICPMS, and allows for the creation of large, distributable standards with improved homogeneity compared to existing silicate glass standards.

Implementation Method 1

Methodology Applied

Scientific EffectElectrophoretic deposition: Electrophoretic Deposition

Data Source

PatentUS12286355B2Additive manufacturing of microanalytical reference materials

Publication Date: 2025.04.29 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

A method includes acquiring particles doped with at least one analyte and forming a monolithic reference material. The method includes forming includes using the analyte-doped particles as feedstock particles in an additive manufacturing process. A product includes a monolithic reference material formed of Stöber particles doped with a trace element. A method includes acquiring particles doped with platinum group elements (PGEs). The method includes forming a monolithic reference material using the PGE-doped particles as feedstock particles in an additive manufacturing process.