Hybrid Solid-State 3D Printing With In-Process Material Removal
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Solution Overview
Problem
Existing additive manufacturing techniques, such as 3D printing, often result in weak spots at interfaces between layers due to inhomogeneous material properties, leading to inferior mechanical performance compared to bulk materials, and require additional tools and equipment for finishing.
Innovation Solution
A hybrid solid-state manufacturing process combining additive and subtractive steps using a hybrid manufacturing system that deposits filler materials through a hollow spindle, applying frictional forces to create a malleable state and then removing material to form a finished part without additional tools, enabling strong bonding and feature formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive manufacturing (3D printing) is used to deposit layers, then 3D objects can be produced, but weak spots are created at interfaces between layers due to inhomogeneous material properties
Solution Approach 1:
The patent applies friction-based severe plastic deformation to fundamentally change the material state at layer interfaces. By applying high frictional forces and pressure during deposition, the material undergoes extreme shear and normal stresses that transform the microstructure from layered to homogeneous, eliminating weak interface regions and achieving bulk-like mechanical properties throughout the entire part.
Solution Approach 2:
The rotating tool applies dynamic mechanical forces through friction that create severe plastic deformation and mixing at the interface zone. This mechanical action continuously works the material during deposition, ensuring homogeneous bonding and eliminating the weak spots that would otherwise form between deposited layers.
2Ease of manufacture
If conventional additive manufacturing is used, then 3D objects can be produced, but additional tools and equipment are required for finishing and feature creation
Solution Approach 1:
The patent integrates additive manufacturing, subtractive machining, and surface finishing operations into a single hybrid tool system. The same tool that deposits material through friction-based severe plastic deformation also performs machining operations, eliminating the need for separate equipment and consolidating multiple manufacturing functions into one device.
Solution Approach 2:
The hybrid manufacturing tool is designed to perform multiple functions: it can deposit filler material, machine the substrate, create complex features, and finish surfaces all in sequence without requiring tool changes or additional equipment. This multi-functional capability reduces device complexity while maintaining full manufacturing capability.
3Strength
If friction-based severe plastic deformation is applied to create malleable state for strong bonding, then interface strength is improved, but process complexity increases
Solution Approach 1:
The patent combines the friction-based severe plastic deformation process with the additive manufacturing operation itself. The same frictional forces that create the malleable state for strong bonding are generated during the normal deposition process, eliminating the need for separate bonding or heat treatment steps and reducing overall process complexity despite the advanced mechanics involved.
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 process produces 3D objects with improved mechanical properties by eliminating weak spots and integrating additive and subtractive steps within a single system, enhancing the bonding between layers and allowing for complex feature creation without additional equipment.
Implementation Method 1
generating plastic deformation, such as severe plastic deformation, of the filler material(s) and the substrate by applying normal, shear and/or frictional forces by way of a rotating shoulder of the hollow spindle or tool
Implementation Method 2
frictional and other forces as well as the generated heat cause significant material deformation in the vicinity of the rotating tool
Implementation Method 3
depositing the filler materials(s) onto a substrate... producing the 3D printed part... generating a good bonding between the deposited material and the workpiece
Data Source
AI summary
Solid-state additive and subtractive manufacturing processes, completely or partially performed by a solid-state manufacturing system, are disclosed. Solid-state deposition processes of different materials for printing 3D parts, coating, joining or repair are included as examples. Subtractive processing steps, such as machining, drilling, surface grooving, surface activation and others are discussed as well. In addition, other processes performed by other means are mentioned in making the final parts.