Metal Additive Manufacturing Sequential Deposition Molten State
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current metal printing technologies, such as Direct Metal Laser Sintering, are expensive and time-consuming due to the need for complex lasers and vacuum chambers, and face challenges like oxidation and surface tension issues that prevent low-cost, efficient metal printing.
Innovation Solution
A new additive manufacturing process involving sequential deposition and heating, where an outer barrier material and inner metal filling are dispensed layer by layer, with the barrier material maintaining the metal in a molten state to prevent oxidation and ensure form accuracy, using high-temperature materials like ceramic composites or fibers to manage surface tension and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If Direct Metal Laser Sintering is used to produce metal parts with high accuracy, then manufacturing precision is improved, but production time increases significantly and cost increases
Solution Approach 1:
The patent changes the state parameter of metal from solid/powder to molten liquid, allowing faster deposition rates while maintaining precision through the barrier material containment system
Solution Approach 2:
The barrier material acts as an intermediary that contains the molten metal, enabling faster production while maintaining form accuracy by preventing oxidation and surface tension issues
2Manufacturing precision
If complex lasers and vacuum chambers are used in metal printing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts and removes the complex laser and vacuum chamber components from the metal printing system, replacing them with a simpler extrusion-based system that uses barrier material to maintain precision
Solution Approach 2:
The barrier material serves as a disposable containment structure that replaces expensive, complex equipment while achieving the same precision goals
3Ease of manufacture
If metal is deposited in solid or powdered state, then ease of manufacture is improved, but oxidation occurs between layers
Solution Approach 1:
The patent changes the temperature state of metal to molten, which eliminates oxidation between layers by maintaining a continuous liquid state that can be contained by the barrier material
Solution Approach 2:
The barrier material acts as an intermediary that prevents oxidation by containing the molten metal from atmospheric exposure during the printing process
4Reliability
If metal is deposited in molten state to prevent oxidation, then reliability is improved, but surface tension effects make form control difficult
Solution Approach 1:
The barrier material serves as a mediator that counteracts surface tension effects by providing physical containment for the molten metal, allowing form accuracy to be maintained while preventing oxidation
Solution Approach 2:
The barrier material provides localized containment exactly where the molten metal is deposited, addressing surface tension issues at the specific location without affecting the overall process
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 method reduces production costs and time by maintaining the metal in a molten state until completion, overcoming oxidation and surface tension issues, resulting in accurate and efficient metal part creation.
Implementation Method 1
The heated print base may maintain the metal filling contained within the cavity formed by the outer barrier in the molten state (e.g., through contact with a heated print base, by proximity to the heated print base)
Implementation Method 2
The heated print base may maintain the metal filling contained within the cavity formed by the outer barrier in the molten state (e.g., through contact with a heated print base, by proximity to the heated print base)
Implementation Method 3
An outer barrier (molding) and an inner metal filling are dispensed consecutively to create an object. The barrier material is extruded first onto a heated print base (a platform) to form the outer barrier, after which the metal filling, typically in the molten state, is also extruded onto the platform within the outer barrier.
Data Source
AI summary
A three-dimensional (3D) printer includes a heated printing surface and a multi-tool extrusion assembly. The multi-tool extrusion assembly includes a barrier extrusion assembly and a metal extrusion assembly. The barrier extrusion assembly includes: a first inlet adapter to receive a barrier material; a first torque-and-pinch assembly, coupled to the first inlet adapter, to receive the barrier material; and a first hot-end assembly, coupled to the first torque-and-pinch assembly, to receive the barrier material and extrude the barrier material to form an outer retaining barrier on the heated printing surface. The metal extrusion assembly includes: a second inlet adapter to receive a metal; a second torque-and-pinch assembly, coupled to the second inlet adaptor, to receive the metal; and a second hot-end assembly, coupled to the second torque-and-pinch assembly, to extrude the metal to form an inner metal filing on the heated printed surface within the outer retaining barrier.