Liquid Metal Jet Printing With Substrate Heating and Oxide Ablation

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Solution Overview

Problem

Existing liquid metal jet printing systems face challenges in controlling thermofluidic processes such as remelting, coalescing, and metallurgical bonding due to low surface temperatures and oxide layers, leading to unsatisfactory article properties and shape inaccuracies.

Innovation Solution

The implementation of a controlled heating and ablation system, utilizing lasers or other high-power sources, to concurrently heat the substrate and ablate oxide layers, thereby regulating interfacial temperatures and facilitating controlled deposition of molten metal droplets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If liquid metal jet printing is performed without additional heating, then the process is simpler, but the surface temperature is insufficient to enable proper remelting and coalescing of metal droplets

Engineering Contradiction:

Improvesurface temperatureVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heating system is integrated with the liquid metal jet printing system by positioning the heating element in close proximity to the substrate and printhead, allowing simultaneous heating and printing operations within a unified system architecture

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The substrate is pre-heated to the required temperature before metal droplet deposition begins, ensuring that the surface is already at the optimal temperature for remelting and coalescing when the printing process starts

Inventive Principle:

Principle #10Preliminary action

2Strength

If oxide layers are present on the substrate, then the substrate can be stored and handled more easily, but the oxide layer inhibits metallurgical bonding between the substrate and metal droplets

Engineering Contradiction:

Improvemetallurgical bondingVSAvoidsubstrate preparation

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The substrate surface is pre-treated through oxidation to form a controlled oxide layer, which is then subsequently removed or modified in situ before printing to enable proper metallurgical bonding

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional mechanical or chemical surface preparation methods are replaced with in situ thermal processing using the integrated heating system, which can selectively remove or modify oxide layers through controlled heating and cooling cycles

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If the substrate is heated to high temperatures to improve bonding, then metallurgical bonding is enhanced, but excessive heat can cause unwanted thermal effects and deformation

Engineering Contradiction:

Improvemetallurgical bondingVSAvoidshape accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The heating system is configured to apply heat locally to specific regions of the substrate where metal droplets will be deposited, rather than heating the entire substrate uniformly, thus achieving high temperatures only where needed for bonding

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The heating system operates in periodic cycles, applying heat pulses synchronized with the droplet deposition process, allowing the substrate to cool between pulses and preventing excessive heat accumulation that could cause deformation

Inventive Principle:

Principle #19Periodic action

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 enhances the quality of fabricated articles by improving remelting, coalescing, and metallurgical bonding, reducing voids and shape errors, while maintaining precise temperature control and removing contaminants.

Implementation Method 1

The output from the laser has a power of from about 40 watts (W) to about 1500 W... The output is configured to concurrently heat the substrate and ablate oxides on a surface of the substrate

Methodology Applied

Scientific EffectOptical energy to thermal energy conversion: Absorption (EM radiation)

Implementation Method 2

The output is configured to concurrently heat the substrate and ablate oxides on a surface of the substrate

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 3

liquid metal jet printing, such as magnetohydrodynamic (MHD) liquid metal jet printing, includes ejecting liquid or molten metal drops or droplets from a printhead... utilizing a direct current pulse applied by an electromagnetic coil to expel molten metal drops

Methodology Applied

Scientific EffectMagnetohydrodynamic effect: Magnetohydrodynamic Effect

Data Source

PatentUS20250360676A1Additive manufacturing systems and methods for the same

Publication Date: 2025.11.27 ADDITIVE TECH LLC DBA ADDITEC

AI summary

An additive manufacturing device includes a stage configured to support a substrate. The device also includes a printhead disposed above the stage. The printhead is configured to heat a build material to a molten build material and to deposit the molten build material on the substrate in the form of droplets to fabricate an article. The device also includes a controlled heating and ablation system disposed proximal the printhead. The controlled heating and ablation system is configured to heat the substrate and ablate oxides on a surface of the substrate.