Functionally Graded Additive Manufacturing via Particle Sedimentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for a method to produce functionally graded materials through additive manufacturing, as traditional approaches often result in material mismatch issues, such as a ceramic coating flaking off due to thermal expansion differences.
Innovation Solution
The method involves using a radiant-energy-curable resin with particles of different properties that settle in distinct regions, allowing for selective curing to create a functionally graded structure layer-by-layer, utilizing a combination of vats, stages, and radiant energy sources to define the geometry of each layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional bulk processing or preform processing is used to fabricate functionally graded materials, then material composition can be controlled, but discrete boundaries between materials are created causing mismatch issues
Solution Approach 1:
The patent applies local quality by varying the filler particle composition and concentration at different spatial locations within the resin. Different regions of the resin contain different proportions of first and second filler particles, creating a functionally graded material with continuously varying properties rather than discrete material boundaries. This eliminates the interface problems that cause coating delamination while maintaining compositional control.
2Adaptability or versatility
If discrete material boundaries are created between different materials, then specific material properties can be achieved in different regions, but thermal expansion mismatch causes coating to flake off
Solution Approach 1:
The patent employs parameter changes by systematically varying the concentration and distribution of filler particles throughout the resin matrix. By controlling the proportion of first and second filler particles at different locations, the material properties (such as thermal expansion coefficient, modulus, etc.) are gradually changed across the component, creating a functionally graded structure that adapts to different functional requirements without creating sharp property transitions that would cause delamination.
3Shape
If additive manufacturing is used to build components layer-by-layer, then complex geometries can be achieved, but ensuring uniform filler distribution in each layer is difficult
Solution Approach 1:
The patent applies preliminary action by pre-mixing the first and second filler particles with the resin to create a homogeneously distributed master batch before the additive manufacturing process. This preliminary mixing ensures that when the resin is deposited layer-by-layer during additive manufacturing, the filler particles are already uniformly distributed, eliminating the need for complex in-situ mixing mechanisms and ensuring consistent filler distribution throughout the built component.
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 approach enables the production of functionally graded components with controlled composition and structure, addressing material mismatch issues by creating distinct regions within the component, enhancing its functional properties.
Implementation Method 1
allowing the filler to settle such that the at least two groups of particles separate from each other
Implementation Method 2
allowing the filler to settle such that the at least two groups of particles separate from each other
Implementation Method 3
Exposure to the radiation cures and solidifies the pattern in the resin and joins it to a previously-cured layer
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method for producing a functionally graded component (74, 174) layer-by-layer includes: depositing radiant-energy-curable resin on a build surface (22) defined by a resin support (12), the resin containing filler including at least two groups of particles with different physical properties; allowing the filler to settle such that the groups of particles separate from each other, defining at least two regions within the resin; positioning a stage (14) relative to the build surface (22) so as to define a layer increment in the resin; selectively curing the resin using an radiant energy applied in a specific pattern so as to define the geometry of a cross-sectional layer of the component (74, 174); moving the build surface (22) and the stage (14) relatively apart so as to separate the component (74, 174) from the build surface (22); repeating at least the steps of positioning and selectively curing for a plurality of layers, until the component (74, 174) is complete.