Additive Manufacturing with Inkjet-Based Local Composition Control
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Solution Overview
Problem
Existing additive manufacturing methods for metal and ceramic workpieces are limited to uniform material compositions, failing to achieve structurally inhomogeneous distributions of carbon, nitrogen, doping elements, and alloying elements, which are crucial for achieving varied material properties in specific regions of the workpiece.
Innovation Solution
An additive manufacturing method utilizing granular materials with a base material and an organic binder, combined with inks containing solvents and additives, allows for the local deposition of different materials by printing patterns that define the material properties in each region, enabling the creation of workpieces with varying compositions through layer-by-layer bonding and thermal treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional additive manufacturing methods use uniform powder material, then the manufacturing process is simple, but the workpiece cannot achieve structurally inhomogeneous distribution of elements for varied material properties
Solution Approach 1:
The patent applies local quality by introducing additives at specific locations within the workpiece using selective inkjet printing. Different additives (carbon, nitrogen, doping elements, alloying elements) are deposited only in regions where specific material properties are required, creating local variations in composition and properties while maintaining a uniform base material throughout the workpiece.
Solution Approach 2:
The manufacturing process is segmented into distinct functional stages: base material deposition, selective additive deposition via inkjet printing, binder removal, and thermal treatment. This segmentation allows each process step to be optimized independently, achieving complex material properties without proportionally increasing overall process complexity.
2Adaptability or versatility
If multiple granular materials are used for different regions, then different material properties can be achieved, but the manufacturing complexity and material handling become significantly more difficult
Solution Approach 1:
The patent creates composite materials by combining a uniform base material with locally deposited additives. Rather than using multiple different granular materials, the final material composition is achieved through a composite structure where the base material provides the matrix and locally deposited additives create region-specific properties, simplifying material handling while achieving composition variation.
Solution Approach 2:
The inkjet printing system acts as an intermediary that delivers additives to specific locations without requiring direct handling of multiple granular materials. The additives are suspended in liquid vehicles that are jetted onto the green compact surface, allowing precise placement while avoiding the complexity of managing multiple powder feeds or hoppers.
3Quantity of substance
If ink contains high concentration of additive suspension, then material properties are enhanced, but the ink viscosity increases making printing difficult
Solution Approach 1:
The patent manages ink properties by adjusting parameters such as solvent composition, temperature, and additive particle size distribution. These parameter changes allow the ink to maintain appropriate viscosity for jetting while still delivering sufficient additive concentration to achieve the desired material properties in the final workpiece.
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 production of workpieces with distinct material properties in different regions, such as varying hardness and resilience, by using a single base material and additives, overcoming the limitations of uniform composition in traditional methods.
Implementation Method 1
An ink contains a solvent for dissolving the organic binder, and a suspension of the additive. The applied ink at least partially dissolves the organic binder in the region of the patterns
Implementation Method 2
The solvent is preferably volatile at room temperature. The solvent is expelled, as a result of which the granular material is locally connected by the organic binder and the additive is fixed
Implementation Method 3
The binder locally bonds the loose powder particles to each other, and the ongoing bonded layer with the preceding layer
Implementation Method 4
The green compact is thermally treated in order to convert the base material and the additive into the material
Data Source
AI summary
A method for a workpiece comprising a material composed of a base material and an additive is disclosed, the method including spreading a granular material in superimposed layers. The granular material contains the base material and an organic binder. An ink contains a solvent for dissolving the binder, and a suspension of the additive. Using the ink, patterns are printed onto individual layers. The ink dissolves the binder in the region of the patterns, and introduces the additive in the region of the patterns. The patterns in the layers together produce a three-dimensional shape of the workpiece. The solvent is expelled so that the granular material is connected by the binder and the additive is fixed. Granular material unwetted by the solvent is removed to reveal the green compact of the workpiece. The green compact is thermally treated to convert the base material and the additive into the material.