Mask-Templated Cold Spray for Fine Functional Material Features
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Solution Overview
Problem
Current additive manufacturing techniques, such as cold spray deposition, are limited in their ability to preserve the microstructure of functional materials like permanent magnets and thermoelectrics, often resulting in reduced density and destroyed functional properties due to melting or high-energy processes, making it difficult to achieve fine feature sizes and high-aspect ratios without significant material loss and increased costs.
Innovation Solution
The use of mask-templated cold spray deposition, which allows for the deposition of fine features without melting the powders, maintaining the microstructure and achieving high densities and functional properties by using a mask to control the deposition of particles and create shadowed regions, enabling the formation of complex shapes and arrays of functional materials with feature sizes below 100 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing techniques (melting processes) are used to fabricate functional materials, then material deposition and shaping are achieved, but the microstructure is destroyed and functional properties are reduced
Solution Approach 1:
The invention changes the fundamental parameter of deposition temperature from melting conditions to below-melting conditions. By controlling the gas temperature and particle velocity, the process deposits material without melting, thereby preserving the microstructure and functional properties of brittle materials while still achieving dense, adherent coatings
Solution Approach 2:
The invention replaces thermal-melting mechanisms with kinetic-energy-based deposition. Supersonic gas flow accelerates particles to high velocities, and the kinetic energy upon impact enables bonding without thermal melting, thus preserving microstructure while achieving material deposition
2Quantity of substance
If conventional magnet manufacturing processes are used, then bulk magnets are produced, but material loss exceeds 25% due to grinding and machining
Solution Approach 1:
The invention enables near-net-shape fabrication where the magnet is built directly to its final form through additive deposition. The process inherently produces the desired geometry without requiring subsequent subtractive machining, achieving material utilization exceeding 95% while maintaining manufacturing feasibility
Solution Approach 2:
The invention deposits material in controlled layers or segments that can be precisely positioned and shaped. By building the magnet incrementally through successive depositions, the process achieves complex geometries and fine features without requiring extensive post-processing machining operations
3Use of energy by moving object
If binder ink-jetting is used to manufacture magnets, then additive manufacturing is achieved, but energy density is reduced by 30% due to high binder volume fraction
Solution Approach 1:
The invention extracts and eliminates the binder component entirely from the manufacturing process. By depositing pure magnetic powder particles directly onto the substrate through supersonic flow, the process achieves additive manufacturing without requiring binders, thereby maximizing energy density while maintaining manufacturing capability
Solution Approach 2:
The invention creates a composite structure where magnetic powder particles are densely packed and bonded through kinetic energy impact. The resulting material structure resembles the original sintered compact with high particle density and minimal interparticle void space, achieving high energy density while maintaining additive manufacturing advantages
4Manufacturing precision
If selective laser melting is used to create fine features, then additive manufacturing with melting is achieved, but the delicate microstructure essential to magnetic properties is destroyed
Solution Approach 1:
The invention changes the deposition parameter from high-temperature melting to controlled kinetic energy impact. By adjusting particle velocity, gas temperature, and deposition conditions, the process achieves fine feature resolution through precise particle placement without thermal melting, thereby preserving magnetic microstructure while maintaining manufacturing precision
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 enables the rapid and efficient fabrication of functional materials with preserved microstructure and high density, achieving enhanced properties such as coercivity in magnets and tailored thermoelectric performance, while reducing material loss and production costs.
Implementation Method 1
Upon impact, the particles plastically deform and bond with the surface or one another
Implementation Method 2
Cold spray deposition of coatings is widely used across industry for corrosion-resistant claddings and localized repair
Implementation Method 3
Cold spray deposition, according to the various aspects described herein, by contrast, does not generally melt the powders and so the microstructure can largely be preserved intact
Data Source
AI summary
A product includes an array of cold spray-formed structures. Each of the structures is characterized by having a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure, at least 90% of a theoretical density of a raw material from which the structure is formed, and essentially the same functional properties as the raw material. A product includes a cold spray-formed structure characterized by having a defined feature size in at least one dimension of less than 100 microns as measured in a plane of deposition of the structure, at least 90% of a theoretical density of a raw material from which the structure is formed, and essentially the same functional properties as the raw material.