High Temperature 3D Print Head for Metal Deposition

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Solution Overview

Problem

Existing 3D printing technologies are limited in their ability to handle high temperature materials such as metals and silicon carbide, as they lack the structural integrity and temperature resistance required for printing these materials effectively, and often require powders and raster scanning processes.

Innovation Solution

A high temperature 3D print head made from materials like tungsten or ceramic composite that maintains structural integrity at temperatures above the melting point of the printed materials, functioning as a modified inkjet printer to deposit high temperature materials like metals and silicon carbide without the need for powders or raster scanning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional 3D printing technologies are used, then printing of common materials is achieved, but structural integrity and temperature resistance are insufficient for high temperature materials

Engineering Contradiction:

Improvetemperature resistanceVSAvoidstructural integrity

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent changes the material parameters of the print head by using tungsten or ceramic composite materials instead of conventional materials. This enables the print head to withstand temperatures above 1000°C while maintaining structural integrity, allowing direct printing of high temperature materials like metals and silicon carbide without requiring powder forms or raster scanning processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material solutions by using ceramic composites or tungsten for the print head construction. These materials provide both the necessary thermal resistance and structural strength to operate at extreme temperatures, enabling direct deposition of high temperature materials in a controlled manner without compromising the print head's integrity.

Inventive Principle:

Principle #40Composite materials

2Productivity

If high temperature materials are printed using conventional methods, then material deposition is achieved, but the process requires powders and raster scanning which reduces efficiency

Engineering Contradiction:

Improveprinting efficiencyVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the unnecessary intermediate steps of powder preparation and raster scanning processes from the conventional 3D printing workflow. By using a specialized high temperature print head, the system directly deposits high temperature materials in a streamlined manner, removing the complexity associated with powder handling and scanning mechanisms while improving printing efficiency.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the complex mechanical raster scanning system with a more efficient direct deposition approach. The high temperature print head enables material to be deposited directly at the desired location through controlled movement, eliminating the need for intricate scanning mechanisms and powder delivery systems, thereby simplifying the overall process and enhancing productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 efficient printing of high temperature materials by maintaining structural integrity and eliminating the need for powders and raster scanning, allowing for the creation of 3D structures with precise control and thin layer thicknesses.

Implementation Method 1

The high temperature print head maintains structural integrity while operation at temperatures above the melting temperature for the material that is being printed

Methodology Applied

Scientific EffectThermal resistance: Thermal Insulation

Implementation Method 2

The print head sweeps a predefined and computer controlled area to layer material at tens of microns layer thicknesses

Methodology Applied

Scientific EffectMaterial deposition: Deposition (physical)

Data Source

PatentUS10807273B2High temperature additive manufacturing print head

Publication Date: 2020.10.20 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

A system of 3D printing using a high temperature 3D print head that functions as a “modified ink jet” printer. The print head has the ability to print high temperature material such as metal, silicon carbide, and other high temperature material as opposed to inks or plastics. The print head is fabricated from a high temperature material to maintain structural integrity while operation at temperatures above the melting temperature for the material that is being printed.