Laser Welded Laminate Additive Manufacturing for Build Speed
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Solution Overview
Problem
Conventional additive manufacturing (AM) techniques face limitations in build speed, porosity, and the need for sacrificial support structures, making them inefficient for mass production and resulting in less dense and weaker 3D objects compared to traditionally manufactured parts.
Innovation Solution
The method involves cutting thicker, pre-programmed 2D slices from input materials, which are then stacked and adhered using localized and directed laser welding techniques, eliminating the need for individual layer curing and reducing waste by using finished materials, thereby increasing build speed and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional additive manufacturing techniques deposit very thin layers of material sequentially, then the deposition process can pass through material without clogging nozzles, but the build speed becomes extremely slow and tedious
Solution Approach 1:
The patent segments the object into multiple laminate layers that are pre-cut from sheets of material. Each layer is cut to a thickness that is substantially uniform and significantly thicker than conventional AM layers (e.g., 0.002 to 0.010 inches), allowing faster processing while maintaining precision through controlled segmentation of the build process into discrete layer assembly steps
Solution Approach 2:
The patent applies preliminary action by pre-cutting all laminate layers from sheets of material before assembly. The layers are pre-programmed with their final shapes and positioned according to the 3D model, eliminating the need for slow sequential deposition during the build process and enabling parallel preparation of multiple layers
2Productivity
If conventional AM techniques cure each deposited layer individually before adding the next layer, then adhesion between layers is achieved, but the build process becomes even more time-consuming
Solution Approach 1:
The patent merges the adhesion function into a single step performed after all layers are assembled. Instead of curing each layer individually, the laminate layers are stacked and adhered together in one operation using heat, pressure, or chemical bonding agents, eliminating repetitive curing cycles and dramatically reducing total build time
Solution Approach 2:
The patent enables continuity of useful action by allowing multiple layers to be prepared and stacked simultaneously without interruption for curing. The assembly process continues uninterrupted with layers being added sequentially to the stack, and the bonding operation is performed continuously on the complete or near-complete assembly rather than pausing between layers
3Productivity
If conventional AM techniques use material deposition through nozzles, then material can be extruded layer by layer, but the nozzles clog when solid material is used and very thin layers must be deposited
Solution Approach 1:
The patent replaces the mechanical nozzle deposition system with a cutting and assembly system. Instead of extruding material through nozzles, sheets of material are cut into laminate layers using cutting tools (laser, waterjet, CNC) and then assembled by stacking and bonding, eliminating nozzle clogging issues entirely while enabling use of solid materials in thicker, more practical layers
Solution Approach 2:
The patent changes the material parameter from extrudable filament or paste to solid sheets that can be cut and laminated. This parameter change allows the use of a broader range of materials including metals, ceramics, and composites that would clog nozzles, while the layer thickness is increased to practical ranges (mils to thousandths of an inch) that eliminate the need for ultra-thin deposition
4Strength
If conventional AM techniques produce 3D objects with layered structures, then the objects can be built from digital models, but the objects have porosity and are less dense and weaker than traditionally manufactured parts
Solution Approach 1:
The patent applies local quality by concentrating bonding energy or adhesive material specifically at the interfaces between laminate layers where adhesion is needed. The bonding process targets the layer interfaces with heat, pressure, or chemical agents applied locally at the bonding surfaces, ensuring strong interlayer adhesion without compromising the density or strength of the bulk material
Solution Approach 2:
The patent uses composite materials by combining multiple laminate layers of the same or different materials to build the 3D object. The layered composite structure, when properly bonded, achieves high density and strength comparable to traditional manufacturing, and can incorporate material gradients or hybrid materials to optimize local properties for strength and performance
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 significantly enhances build rates, reduces material handling hazards, and produces stronger 3D objects with reduced porosity and minimal waste, addressing the inefficiencies of conventional AM techniques.
Implementation Method 1
the laser is used to weld adjacent laminate layers together
Implementation Method 2
The laser is lowered into contact with the laminate layers and the laser is used to weld adjacent laminate layers together
Data Source
AI summary
A system and method are provided for implementing localized and directed laser welding joining techniques in a process of building up laminate layers to form and/or manufacture three-dimensional objects, parts and components (3D objects). A multi-stage 3D object forming scheme is described involving steps of laminate cutting (with lasers or other cutting devices); laminate transport between processing stations (including using one or more of conveyors, robotic pick and place devices and the like); laminate stacking, clamping and adhering through a targeted laser welding technique; and mechanical surface finishing (via CNC machining or other comparable process).