Ejector for In Situ Metal Composition Modification
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Solution Overview
Problem
Current additive manufacturing technologies using drop-on-demand jetting for metal parts lack the ability to modify compositions in situ, limiting the potential for improved quality, cost-effectiveness, and process productivity.
Innovation Solution
The development of an ejector system that incorporates a nozzle orifice, gas sources, and an additive source to modify the composition of liquid metal droplets in real-time during the jetting process, allowing for instantaneous changes to the physical or chemical properties of the printing material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional drop-on-demand jetting is used for metal parts, then the manufacturing process is simple and efficient, but the ability to modify compositions in situ is lost
Solution Approach 1:
The patent implements nesting by placing an inner cavity containing printing material inside the ejector body, and further nesting an additive source within the ejector system. The inner cavity is positioned within the ejector body, and the additive source is integrated into the ejector structure, allowing multiple functional components to be contained within each other to achieve composition modification without excessive external complexity
Solution Approach 2:
The patent uses gas as an intermediary medium to transport additive material from the additive source to the printing material in the inner cavity. The gas flows through a gas passage and interacts with the printing material, enabling composition modification without direct contact between the additive source and the metal droplets, thus resolving the contradiction between functionality and complexity
2Manufacturing precision
If in situ modification is implemented during printing, then parts with tailored properties can be created, but the process complexity increases
Solution Approach 1:
The patent enables local quality modification by allowing selective addition of additives to specific regions of the printing material. The additive source can be positioned and controlled to deliver additives to specific areas of the inner cavity, creating parts with spatially varying properties such as composite structures in specific zones while maintaining simple base material elsewhere
Solution Approach 2:
The patent implements parameter changes by modifying the composition, temperature, or concentration of the printing material in real-time during the jetting process. The additive source introduces substances that change the physical or chemical parameters of the printing material, enabling tailored part properties through dynamic parameter adjustment rather than fixed material properties
3Reliability
If multiple additives are introduced during printing, then material properties improve, but the risk of contamination increases
Solution Approach 1:
The patent employs an inert atmosphere by using gas as a carrier medium to transport additives. The gas creates a controlled environment that prevents unwanted oxidation or contamination of the molten metal printing material while delivering additives. This inert or controlled atmospheric approach reduces harmful factors associated with direct exposure to air or uncontrolled environments during the additive introduction process
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 solution enables the creation of parts with tailored properties, such as composite, nanocomposite, or alloy structures, improving mechanical properties, bonding, and reducing porosity, while also allowing for the printing of alloys that are difficult to manufacture conventionally.
Implementation Method 1
a coil wrapped at least partially around the ejector, and a power source configured to supply one or more pulses of power to the coil, which cause the one or more droplets of liquid metal to be jetted out of the nozzle orifice
Implementation Method 2
a heating element configured to heat a solid in the inner cavity of the ejector, thereby causing the solid to change to a liquid within the ejector
Implementation Method 3
a first gas source associated with the inner cavity and an external portion of the nozzle
Implementation Method 4
a second gas source coupled to the first gas source and in proximity to an external portion of the nozzle orifice
Data Source
AI summary
An ejector for jetting modified metal is disclosed. The ejector for jetting modified metal also includes a nozzle orifice in connection with the inner cavity and configured to eject one or more droplets of liquid metal. The ejector for jetting modified metal includes a first gas source associated with the inner cavity and an external portion of the nozzle. The ejector for jetting modified metal also includes a second gas source coupled to the first gas source and in proximity to an external portion of the nozzle orifice.