Laser-Sintered Ceramic Additive Manufacturing for Crack-Free Density

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Additive manufacturing of inorganic materials with high melting points and the integration of laser-material processing are challenging due to the lack of effective in-situ processing techniques, particularly for forming complex geometries and achieving high-density, crack-free ceramic components.

Innovation Solution

The method involves depositing silica sol-gel coatings or ceramic pastes on substrates and using a CO2 laser for sintering, with specific scanning patterns and power densities to form dense silica films, ceramic components, and 3D printing of fused silica glass, while also applying rapid laser reactive sintering for protonic ceramic energy devices and optical fiber sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If additive manufacturing is used to form 3D ceramic components, then complex geometries can be achieved, but high melting point materials and crack-free dense structures are difficult to obtain

Engineering Contradiction:

Improvecomplex geometryVSAvoidcrack-free dense structure

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent combines additive manufacturing with laser processing in an integrated system, where the laser module is incorporated into the AM apparatus. This merging allows in-situ sintering and processing of ceramic materials during the additive manufacturing process, enabling complex geometries to be formed while simultaneously achieving dense, crack-free structures through controlled laser heating and sintering parameters.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs precise control of laser processing parameters including power density, scanning speed, and focal position to optimize the sintering process. By dynamically adjusting these parameters during additive manufacturing, the system achieves complete densification of high melting point ceramic materials without forming cracks, while maintaining the ability to create complex 3D geometries.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If laser processing is integrated with additive manufacturing, then in-situ materials processing can be achieved, but system complexity increases

Engineering Contradiction:

Improvein-situ processing capabilityVSAvoidintegrated system structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The integrated system is designed with multi-functional capabilities where the laser module serves multiple purposes: sintering ceramic green bodies, processing finished ceramic components, and potentially melting metals. The control system coordinates both additive manufacturing and laser processing functions through a unified interface, enabling in-situ processing while managing system complexity through functional integration rather than separate independent systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If high laser power density is used for sintering ceramic coatings, then high-density components can be formed, but processing control and crack prevention become more difficult

Engineering Contradiction:

Improvehigh-density structureVSAvoidprocessing control

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The system incorporates feedback control mechanisms where processing parameters are monitored and adjusted in real-time based on the sintering progress and material response. The control system regulates laser power density and scanning speed to maintain optimal conditions for achieving high density while preventing excessive heating that could cause cracking, thereby balancing manufacturing precision with ease of operation.

Inventive Principle:

Principle #23Feedback

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 high-density, crack-free ceramic components with complex geometries, improved transparency in glass components, and rapid manufacturing of protonic ceramic energy devices, while maintaining control over porosity and microstructure.

Implementation Method 1

sintering the coating by scanning the coating using a CO2 laser to form the silica film

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

scanning the coating includes scanning the coating in a straight line track of about 10 mm, at a fixed scanning speed of about 0.1 mm/sec, and using a laser power density of about 0.7 W

Methodology Applied

Scientific EffectThermal energy transfer: Heating

Implementation Method 3

scanning the layer of ceramic paste using a CO2 laser to form a laser-melted layer of ceramic

Methodology Applied

Scientific EffectLaser melting: Laser

Implementation Method 4

scanning the layer of ceramic paste at a fixed scanning speed of at least about 3.5 mm/sec

Methodology Applied

Scientific EffectThermal energy transfer: Heating

Implementation Method 5

using a CO2 laser for sintering, with specific scanning patterns and power densities

Methodology Applied

Scientific EffectElectromagnetic radiation: Laser

Data Source

PatentUS12053906B2Integrated additive manufacturing and laser processing systems and methods for ceramic, glass, and silicon carbide applications

Publication Date: 2024.08.06 CLEMSON UNIV RES FOUND

AI summary

A method for fabricating a protonic ceramic energy device includes: coating an electrolyte layer on an anode layer; and densifying the electrolyte layer by a rapid laser reactive sintering (RLRS) process on the electrolyte layer and/or the anode layer to form a half-cell comprising a dense electrolyte and a porous anode.