Foil-Layer Laser Additive Manufacturing Without Post-Processing
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Solution Overview
Problem
Powder-based additive manufacturing processes are slow, expensive, and require extensive post-processing, limiting their ability to produce high volumes of 3D components quickly and inexpensively.
Innovation Solution
A foil-based additive manufacturing system and method that uses lasers to weld and ablate successive foil layers, allowing for rapid construction of 3D components without the need for post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If powder-based additive manufacturing processes are used, then 3D components can be produced with complex geometries, but production speed is slow and costs are high
Solution Approach 1:
The patent changes the material form parameter from powder to foil, and modifies the laser processing parameters (using ultrafast pulsed lasers with durations of 0.5-10 ps) to achieve rapid material removal and consolidation. This parameter change enables the process to complete in minutes rather than hours or days, eliminating the need for post-processing while maintaining geometric complexity
Solution Approach 2:
The patent replaces traditional mechanical post-processing operations (support removal, surface finishing) with a purely laser-based process. The ultrafast laser ablation and instantaneous consolidation eliminate the need for mechanical intervention, substituting mechanical systems with optical-field-based processing that inherently produces finished surfaces
2Ease of manufacture
If powder-based additive manufacturing is used, then components can be manufactured, but material cost is high and recycling is difficult
Solution Approach 1:
The patent changes the material form from powder to foil, which fundamentally alters the cost structure and recyclability. Foil material is significantly cheaper than metal powder and can be easily recovered and reused by unrolling and repositioning, transforming the material economy from expensive single-use powder to inexpensive recyclable foil
Solution Approach 2:
The patent employs inexpensive foil material that can be easily replaced and recycled, rather than expensive powder that is difficult to recover. The foil serves as a disposable-like material during processing but is actually recyclable, creating a low-cost, high-recyclability material system
3Productivity
If conventional laser processing is used, then material can be removed, but production speed is limited
Solution Approach 1:
The patent employs ultrafast pulsed laser operation with pulse durations of 0.5-10 ps, using periodic ultra-short pulses to remove material through nonlinear absorption and plasma formation. This periodic ultrafast action achieves rapid material removal with minimal heat input, enabling high processing speeds without requiring excessive continuous power
Solution Approach 2:
The patent utilizes phase transition mechanisms unique to ultrafast laser processing, where material transitions directly from solid to plasma/vapor through nonlinear optical absorption and Coulomb explosion. This phase transition pathway bypasses melting and resolidification, enabling extremely rapid material removal with minimal thermal diffusion and high processing speed
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
The foil-based system significantly increases production speed, potentially by 100 times compared to powder-based systems, while reducing costs and enabling large-volume, continuous manufacturing applications.
Implementation Method 1
laser welding the foil layer to the substrate
Implementation Method 2
laser welding the foil layer to the substrate
Implementation Method 3
laser ablating the foil layer using a pulsed laser beam to remove at least a portion of the foil layer, the pulsed laser beam comprising optical pulses with a pulse duration in a range from 0.5 picoseconds (ps) to 10 ps inclusive
Implementation Method 4
laser ablating the foil layer using a pulsed laser beam to remove at least a portion of the foil layer
Data Source
AI summary
A method and system for additive manufacturing is disclosed. In one example, the method comprises (a) positioning a foil layer onto a substrate, (b) laser welding the foil layer to the substrate, (c) laser ablating the foil layer using a pulsed laser beam to remove at least a portion of the foil layer, the pulsed laser beam comprising optical pulses with a pulse duration in a range from 0.5 ps to 10 ps inclusive, and (d) repeating steps (a) to (c) until the 3D component is completed.