Additive Metal Tooling Infiltration for Thermal Conductivity
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Solution Overview
Problem
Additive manufacturing of large-scale structural tools and dies for injection molding faces challenges in material efficiency, printing time, and design flexibility, particularly in creating complex geometries and internal structures like conformal cooling channels, which are time-consuming and material-intensive in traditional subtractive manufacturing methods.
Innovation Solution
The method involves 3D printing a metal object with a solid shell and patterned infill, followed by infiltration with a second metal having a lower melting temperature, such as copper, to enhance thermal conductivity and structural integrity, while minimizing material usage and printing time, using techniques like gyroid or alternating stacked rectangular infill geometries and protectant coatings to control infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing is used to create complex geometries and internal structures, then manufacturing precision and structural integrity are improved, but material efficiency deteriorates and printing time increases
Solution Approach 1:
The patent applies local quality by using patterned infill structures (such as gyroid or alternating stacked rectangular patterns) within the interior volume of the tool, rather than uniform solid construction. This allows material to be strategically placed where structural support is needed while maintaining complex geometries and internal channels, thereby improving material efficiency without sacrificing structural integrity.
Solution Approach 2:
The patent employs composite materials by combining a first metal (such as steel or titanium) for the shell and infill structures with a second metal (such as copper or magnesium) that is infiltrated into the interior volume. This composite approach enables the tool to achieve enhanced thermal conductivity and structural properties while using less material compared to traditional solid construction methods.
2Reliability
If traditional subtractive manufacturing is used to create conformal cooling channels, then leak resistance is improved, but printing time and material usage increase
Solution Approach 1:
The patent applies segmentation by dividing the tool construction into distinct phases: first printing the shell and infill structures with integrated channel geometries, then separately infiltrating the interior volume with a second metal. This segmentation allows complex conformal cooling channels to be created through additive manufacturing's design flexibility while the infiltration process ensures leak resistance by filling and sealing the channel structures.
Solution Approach 2:
The patent utilizes parameter changes by transforming the second metal from solid to liquid state through heating above its melting temperature, enabling it to flow into and fill the interior volume and channel structures. This phase change allows the infiltration process to occur without requiring complex machining operations, thereby reducing printing time while maintaining leak resistance.
3Strength
If solid metal construction is used for tooling, then structural integrity is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent employs composite materials by combining a first metal (such as steel or titanium) for the shell and infill structures with a second metal (such as copper or magnesium) that is infiltrated into the interior volume. This composite approach enables the tool to achieve enhanced thermal conductivity and structural properties while using less material compared to traditional solid construction methods.
4Loss of substance
If additive manufacturing with infill patterns is used, then material efficiency is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent applies local quality by using patterned infill structures (such as gyroid or alternating stacked rectangular patterns) within the interior volume of the tool, rather than uniform solid construction. This allows material to be strategically placed where structural support is needed while maintaining complex geometries and internal channels, thereby improving material efficiency without sacrificing structural integrity.
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 results in composite metal tooling with improved thermal conductivity, compressive stiffness, and leak resistance, reducing printing and processing times, and enabling the production of large, complex parts with enhanced performance characteristics compared to traditional methods.
Implementation Method 1
a second metal having a lower melting temperature than the first metal. When melted and infiltrated, the second molten metal substantially surrounds the infill patterned structures thereby filling the space within the interior volume of the part
Implementation Method 2
infiltrating the part with a second metal having a lower melting temperature than the first metal
Implementation Method 3
applying a protectant on an outside surface of the part before infiltration to prevent the second metal from freely flowing in areas where it is not intended by a user
Data Source
AI summary
Metal composites, tooling and methods of additively manufacturing these are disclosed. Metal objects and structures as provided herein are additively manufactured from metal having an infill pattern infiltrated with a second metal. Also provided herein are methods of forming such objects and structures. Methods include additively manufacturing a metal structure having an interior printed using an infill. Steps can further include infiltrating the printed infill of the structure with a liquid metal thereby forming a bi-metal composite.