Engineered Glass Feedstocks for Custom Composition Gradients

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Solution Overview

Problem

Conventional glass processing methods struggle to achieve custom-tailored composition profiles, particularly in additive manufacturing, due to limitations in controlling composition gradients, thermal stresses, and porosity, leading to suboptimal material homogeneity and transparency in glass components.

Innovation Solution

Direct ink writing (DIW) additive manufacturing with continuous in-line mixing of glass-forming species and dopants in a high viscosity suspension, allowing for the formation of glass structures with custom composition profiles before drying, which are then heat-treated to achieve desired properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional melt production methods are used with batched raw materials, then glass components can be produced with standard compositions, but custom-tailored composition profiles and gradients cannot be achieved

Engineering Contradiction:

Improvecomposition profile controlVSAvoidcomposition homogeneity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The raw materials are segmented into discrete particles with controlled sizes (e.g., 1-10 micrometers) rather than being batched as bulk powders. This segmentation allows individual particles to be precisely placed and distributed during additive manufacturing, enabling custom composition profiles while maintaining homogeneity through controlled particle arrangement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the glass component are assigned different particle compositions and sizes to create spatially varying properties. For example, larger particles may be concentrated in certain zones while smaller particles are distributed in other zones, allowing each local region to have optimized composition for its specific functional requirements

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If additive manufacturing is used to create glass structures, then custom composition profiles can be formed, but thermal stresses and porosity lead to reduced transparency and structural integrity

Engineering Contradiction:

Improvecomposition gradient controlVSAvoidstructural integrity and transparency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The raw material particles are pre-characterized and pre-sorted for size, shape, and composition before manufacturing. This preliminary preparation ensures that when particles are deposited during additive manufacturing, they already have the optimal properties needed to minimize thermal stress and porosity, thereby maintaining structural integrity and transparency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The particle size distribution is carefully controlled and adjusted as a key parameter. By using narrowly distributed particle sizes (e.g., 1-10 micrometers) rather than broad distributions, the material exhibits more uniform thermal and mechanical properties during processing, reducing thermal stress and improving final component reliability

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If diffusion-based gradient methods are used, then composition gradients can be introduced, but the gradients are limited to symmetric parabolic profiles and small diameters

Engineering Contradiction:

Improvegradient profile varietyVSAvoidmaximum achievable diameter

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

Instead of relying on diffusion to create gradients, the material is segmented into particles of different compositions that are directly placed in their final spatial positions during additive manufacturing. This eliminates the need for diffusion-based gradient formation, allowing arbitrary gradient profiles (linear, exponential, step-functions) and much larger component diameters

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Rather than starting with a uniform composition and using diffusion to create gradients (the conventional approach), the invention inverts the process by directly depositing particles with pre-determined compositional variations in their final spatial arrangement, creating gradients through placement rather than diffusion

Inventive Principle:

Principle #13The other way round (Inversion)

4Ease of manufacture

If raw materials with varying particle sizes and shapes are used in conventional processing, then material blending is simplified, but control over processing parameters and material homogeneity is reduced

Engineering Contradiction:

Improvematerial blendingVSAvoidprocessing parameter control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The particle size is controlled as a critical parameter with narrow distributions (e.g., 1-10 micrometers) rather than broad distributions. This parameter control enables precise manipulation of material flow, packing, and melting behavior during additive manufacturing, allowing both easy blending and precise processing control to coexist

Inventive Principle:

Principle #35Parameter changes

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

Enables the creation of optical and non-optical glass components with larger, more controlled composition gradients and improved homogeneity, surpassing the limitations of conventional methods by ensuring structural integrity and transparency.

Implementation Method 1

heat treating the formed structure for converting the glass-forming material to glass

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

continuous in-line mixing of glass-forming species and dopants in a high viscosity suspension

Methodology Applied

Scientific EffectMixing:

Implementation Method 3

dried to a consolidated form

Methodology Applied

Scientific EffectDrying: Desiccation

Data Source

PatentUS20250289968A1Engineered feedstocks for additive manufacture of glass

Publication Date: 2025.09.18 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

A composition includes a glass-forming material and a solvent. A composition includes a glass-forming material that includes mixed composition particles and a solvent.