Hybrid Metal Drop Ejecting and Deposition System for Perimeter Precision
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Solution Overview
Problem
Existing metal drop ejecting and metal deposition systems face challenges in forming fine features and complex perimeters efficiently, as well as infilling interiors quickly, due to limitations in ejection frequency, drop size, and layer formation characteristics.
Innovation Solution
A hybrid manufacturing system that combines a metal drop ejecting device with a metal deposition device, where the controller generates a layer model to identify perimeter and interior portions, and operates the devices accordingly to form fine features and complex perimeters with the drop ejecting device while infilling interiors more quickly with the deposition device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single ejector operates at high ejection frequency to reduce formation time, then productivity improves, but manufacturing precision deteriorates because fine features and complex perimeters cannot be formed adequately
Solution Approach 1:
The patent divides the object formation process into two distinct segments: perimeter formation using a drop ejecting device and interior infill using a metal deposition device. This segmentation allows each device to be optimized for its specific function - the drop ejecting device can operate at lower frequencies to form precise perimeters while the deposition device handles rapid interior filling, thus resolving the contradiction between speed and precision.
2Productivity
If multiple printheads or nozzles are used to increase material dispensing rate, then productivity improves, but device complexity increases and maintaining adequate metal supply becomes difficult
Solution Approach 1:
The patent merges two different metal forming technologies - drop ejecting and metal deposition - into a single hybrid system. Instead of using multiple nozzles of the same type, the system combines a drop ejecting device for perimeter work with a metal deposition device for interior infill, achieving high productivity through technological complementarity rather than numerical multiplication, thereby avoiding the complexity of coordinating multiple similar printheads.
3Productivity
If metal deposition device is used to infill interiors quickly, then productivity improves, but manufacturing precision deteriorates because deposition creates larger metal spots making fine features difficult
Solution Approach 1:
The patent applies local quality by assigning different devices to different regions of the object - the drop ejecting device forms the perimeter portions where precision is critical, while the metal deposition device fills the interior regions where speed is more important. This spatial differentiation of device functions allows each technology to operate in its optimal performance zone, resolving the contradiction between infill speed and fine feature capability.
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 system enables the formation of metal objects with smooth, strong perimeters and rapid infill of interiors, improving production efficiency by leveraging the strengths of both metal drop ejecting and metal deposition technologies.
Implementation Method 1
An electrical current is passed through the conductor to produce an electromagnetic field to cause the meniscus of the melted metal at a nozzle of the chamber to separate from the melted metal within the chamber and be propelled from the nozzle
Implementation Method 2
a plurality of laser light fibers emanating from a plurality of laser light sources to produce a plurality of off-axis laser light beams that can meet at a focal point of a wire end, metal powder and the laser beams
Data Source
AI summary
A metal hybrid manufacturing apparatus includes a melted metal drop ejecting device and a metal deposition device. The melted metal drop ejecting device is operated to form perimeters of layers in a metal object being formed by the system. The metal deposition device is operated to fill interior portions of the layers.