Foil Deposition on 3D-Printed Substrates for Embedded Conductors
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Solution Overview
Problem
Current additive manufacturing techniques do not allow for easy integration of sensors and dissimilar materials, such as conductive devices, into parts being manufactured, as they cannot simultaneously lay down both the substrate and conductive traces.
Innovation Solution
A method involving the deposition of build powder layers, application of foil sheets, and controlled melting of selected portions using a directed energy source, with a system comprising a build platform, recoater, foil feed assembly, and controller to form parts with dissimilar materials by repeating these steps until completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing techniques are used, then the substrate can be manufactured, but sensors and conductive devices cannot be integrated into the part
Solution Approach 1:
The patent combines multiple materials (powder and foil) and multiple functions (substrate building, sensor embedding, conductive trace formation) into a single additive manufacturing process. The directed energy source simultaneously melts both powder and foil materials, allowing sensors and conductive devices to be integrated directly into the part during manufacturing rather than requiring separate post-processing steps.
Solution Approach 2:
The invention uses composite material deposition by alternating between powder layers and foil sheets. The foil material provides dissimilar material properties (such as conductivity or sensor functionality) while the powder forms the substrate structure. This composite approach enables the part to have multiple material properties within a single manufactured component.
2Adaptability or versatility
If dissimilar materials are deposited in the same process, then integration of sensors and conductive devices is enabled, but the device complexity increases
Solution Approach 1:
The directed energy source is designed to universally process multiple material types (powder and foil) using the same energy delivery mechanism. The system uses a single directed energy source rather than requiring separate heating or melting systems for different materials, reducing overall device complexity while maintaining multi-material capability.
Solution Approach 2:
The foil acts as an intermediary material that can be selectively melted to form conductive traces or sensor embedment layers within the powder-based substrate. This intermediary approach allows dissimilar materials to be integrated through a controlled deposition and melting process rather than requiring complex multi-step manufacturing sequences.
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 parts with embedded sensors and conductive pathways, allowing for the integration of dissimilar materials like metals and plastics, enhancing the capabilities of additive manufacturing by forming complex structures with shared energy sources.
Implementation Method 1
melting selected portions of the layer of build powder
Implementation Method 2
a directed energy source, with a system comprising a build platform, recoater, foil feed assembly, and controller to form parts with dissimilar materials
Data Source
AI summary
An additive manufacturing system and method for forming a part of dissimilar materials. The additive manufacturing system may include a build platform, a recoater for dispensing build powder onto the build platform, an energy source, a foil feed assembly, and a controller for controlling actuation of these components. The method of forming the part may include the steps of depositing a layer of build powder onto the build platform surface, melting selected portions of the layer of build powder, applying a sheet of foil over the layer of build powder, melting selected portions of the sheet of foil onto the layer of build powder, removing the sheet of foil from the layer of build powder, and then lowering the build platform surface to prepare for deposition of a next layer of the build powder. These steps are then repeated one or more times, thereby forming the part.