Additive Manufactured Composite Lattice with Encasing Matrix
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Solution Overview
Problem
Existing additive manufacturing (AM) methods face limitations in dispersing high volumes of filler materials into host materials, leading to deleterious effects on mechanical properties and resulting in an unacceptable tradeoff between desirable material properties and desired physical performance.
Innovation Solution
The approach involves organizing filler materials into localized mesoscale regions of high filler loading within the host material, using additive manufacturing to create articles with a lattice material and a structurally sound encasing matrix, thereby overcoming the limitations of traditional filler dispersion methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If high volumes of filler materials are dispersed into host materials using traditional additive manufacturing methods, then the physical performance (e.g., electromagnetic, optical properties) is improved, but the mechanical properties deteriorate due to deleterious effects
Solution Approach 1:
The patent divides the material structure into two distinct segments: a lattice material region with high filler loading for physical performance and an encasing matrix region with low filler loading for mechanical strength. This spatial segmentation allows each region to be optimized independently for its primary function, resolving the contradiction between physical performance and mechanical properties.
Solution Approach 2:
The patent applies local quality by creating spatially varying filler concentrations within the additively manufactured article. The lattice material has high filler concentration for electromagnetic/optical properties, while the encasing matrix has low filler concentration for structural integrity. This non-uniform distribution allows simultaneous optimization of both physical performance and mechanical properties in different locations.
2Adaptability or versatility
If filler materials are dispersed uniformly throughout the host material, then the physical properties are enhanced, but the mechanical toughness deteriorates
Solution Approach 1:
The patent segments the material into functional zones: a lattice material zone with high filler loading for physical property enhancement and an encasing matrix zone with minimal filler for mechanical toughness. This segmentation prevents uniform dispersion from compromising mechanical properties while still achieving the desired physical property enhancement in the lattice region.
Solution Approach 2:
The patent implements local quality by concentrating filler materials specifically in the lattice material region where they are needed for physical performance, while keeping the encasing matrix region filler-free or low-filler to maintain mechanical toughness. This localized approach allows physical property enhancement without sacrificing mechanical reliability.
3Adaptability or versatility
If high filler loading is achieved through conventional dispersion methods, then the desired physical performance is obtained, but the surface finish deteriorates
Solution Approach 1:
The patent segments the article into a lattice material region with high filler loading for physical performance and an encasing matrix region with smooth, low-filler composition for superior surface finish. This segmentation allows the surface (in the encasing matrix) to maintain high manufacturing precision while the interior lattice region achieves the desired physical performance through high filler loading.
Solution Approach 2:
The patent applies local quality by restricting high filler loading to the interior lattice material region while maintaining a filler-free or low-filler encasing matrix that provides a smooth, precise surface finish. This spatial differentiation allows simultaneous achievement of physical performance and surface quality without compromise.
Data Source
AI summary
An additively manufactured article is assembled from a plurality of printed voxels. The article includes a lattice of unit cells of a composite lattice material and an encasing matrix of structural material arranged between adjacent unit cells of the lattice. The structural material has greater mechanical strength than the composite lattice material.