Architected 3D Porous Material via Ceramic Bead Templates
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Solution Overview
Problem
Current methods for producing architected three-dimensional metallic and composite materials face challenges in achieving regular structures, high reproducibility, and cost-effectiveness, particularly in terms of porosity control and production costs, especially for open-cell foams which have high porosity and closed-cell foams which struggle with regularity and porosity levels.
Innovation Solution
The development of an architected three-dimensional material comprising a set of unit cells with hollow structures and orifices, arranged to form a one-piece structure that can be deformed elastically and plastically, connected by a support structure, allowing for efficient energy dissipation and absorption, and manufactured using additive techniques to achieve desired geometries and porosity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If foundry or metallurgy methods are used to manufacture open-cell foams, then regular three-dimensional structures can be obtained with high reproducibility, but the production cost becomes very high
Solution Approach 1:
The invention uses porous ceramic beads as core elements around which metal material is deposited, creating a controlled porous structure. This approach allows regular three-dimensional structures to be formed through a different mechanism than traditional foundry methods, achieving both structural regularity and cost reduction by using simpler, more economical manufacturing processes
Solution Approach 2:
The invention creates a composite structure consisting of ceramic beads embedded in a metal matrix. This composite approach combines the advantages of regular ceramic bead structures with the mechanical properties of metal, enabling regular three-dimensional structures to be produced at lower costs through a hybrid material system rather than relying on expensive pure metal foundry methods
2Productivity
If injection method is used to manufacture closed-cell foams, then production can be performed, but regular structures cannot be obtained and control is difficult, impacting reproducibility
Solution Approach 1:
The invention employs porous ceramic beads with predetermined regular structures as templates. These beads provide a pre-formed regular three-dimensional architecture that is preserved during the metal deposition process, ensuring structural regularity is maintained regardless of the production volume or injection method used
Solution Approach 2:
The regular structure of the porous ceramic beads serves as a template or copy that is replicated in the final metal foam structure. The metal material conforms to the bead arrangement, copying the regular three-dimensional pattern of the ceramic template, thereby ensuring reproducible regular structures across different production batches
3Ease of manufacture
If infiltration of preform method is used, then regular structures can be obtained at low costs, but porosity level is reduced
Solution Approach 1:
The invention uses porous ceramic beads with controlled pore structures as core elements. The metal deposition process is designed to preserve these pores rather than fill them completely, maintaining high porosity levels. This approach allows cost-effective production of regular structures while preserving the quantity of void space needed for high porosity
4Manufacturing precision
If infiltration of lost pattern mould method is used, then regular structures with high porosity can be obtained, but production cost becomes very high
Solution Approach 1:
The invention uses reusable porous ceramic beads instead of single-use lost pattern moulds. The beads can be recovered and reused multiple times, eliminating the high cost associated with creating and disposing of lost pattern moulds for each production run, while still achieving regular structures with high porosity
Solution Approach 2:
The invention recovers and reuses the porous ceramic bead templates after the metal deposition process. Instead of discarding the moulds as in the lost pattern method, the beads are recovered, cleaned, and reused for subsequent production cycles, dramatically reducing production costs while maintaining the ability to produce regular high- porosity structures
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 results in materials with improved mechanical, acoustic, and thermal properties, reduced density, and enhanced deformation capabilities, while minimizing production costs and achieving high porosity levels, thus addressing the limitations of existing methods.
Implementation Method 1
forming, by additive manufacturing from a base material, a set of unit cells, called cells, forming a one-piece three-dimensional structure
Implementation Method 2
discharging the base material contained in the at least one cell to the outside of the at least one cell through the at least one orifice
Data Source
AI summary
An architected three-dimensional material including a set of elementary patterns forming a one-piece structure is disclosed. Each of the patterns has a three-dimensional structure. At least one pattern has a hollow three-dimensional structure and includes at least one hole by means of which a cavity in the at least one pattern is connected to the exterior of the at least one pattern.