Metal Micro-Wire Droplet Jetting for Precise 3D Deposition
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Solution Overview
Problem
Current additive manufacturing techniques, such as LIFT, face inefficiencies in material usage and cost due to the use of metal foils, which result in waste and higher production costs, and lack precision in forming 3D structures.
Innovation Solution
The use of metal micro wires, supported by a glass substrate and heated by a pulsed laser or other heating arrangements, to create metal droplets that are jetted and solidified into 3D structures, allowing for precise control and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If metal foils are used in LIFT process, then droplets can be formed and ejected, but material waste increases and production cost rises
Solution Approach 1:
The patent changes the physical form of the metal material from foil to micro wire, and modifies the heating method parameters (pulsed laser duration, power density) to achieve precise droplet formation with minimal material consumption. This parameter optimization reduces material waste while maintaining manufacturing feasibility
Solution Approach 2:
The invention applies localized heating only at the specific region where droplet formation is needed, rather than heating the entire foil. The pulsed laser targets a small area on the micro wire to create precise droplets, reducing overall material waste and improving cost efficiency
2Manufacturing precision
If metal foils are used in LIFT process, then droplets can be ejected, but precision in forming 3D structures decreases
Solution Approach 1:
The patent segments the continuous metal micro wire into discrete droplets through controlled pulsed laser heating. Each droplet can be precisely positioned and deposited, enabling high-precision 3D structure formation while maintaining a relatively simple manufacturing process
Solution Approach 2:
The invention uses periodic pulsed laser heating to sequentially form and eject droplets at controlled intervals. This periodic action allows precise control over droplet formation timing and position, enhancing manufacturing precision without significantly complicating the overall process
3Manufacturing precision
If pulsed laser heating is applied to metal micro wire, then precise droplet formation is achieved, but energy consumption increases
Solution Approach 1:
The patent applies partial heating action by using short-duration pulsed laser heating only at the specific location where droplet formation is required, rather than continuous heating of the entire micro wire. This partial action achieves precise droplet formation while minimizing overall energy consumption
Solution Approach 2:
The invention uses periodic pulsed laser heating instead of continuous heating, applying energy only when and where droplet formation is needed. This intermittent energy application maintains high manufacturing precision while significantly reducing total energy consumption compared to continuous heating methods
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 enhances precision and reduces waste by serially forming metal droplets from micro wires, lowering production costs and improving the efficiency of 3D structure formation in additive manufacturing.
Implementation Method 1
A laser is positioned to emit, under the control of a controller, a light pulse towards the nozzle area where the end of the metal micro wire is positioned by the piezo translator, thereby causing an end portion of the metal micro wire near the nozzle area to be heated
Implementation Method 2
Local heating caused by the laser causes a droplet of the metal foil to be jetted
Implementation Method 3
The piezo translator may include one or more piezo ceramics arranged to move the metal micro wire in a defined direction upon application of an electric current under the control of the controller
Implementation Method 4
which droplets, when solidified in the aggregate, form 3D structures
Data Source
AI summary
Systems and methods for additive manufacturing, and, in particular, such methods and apparatus as employ pulsed lasers or other heating arrangements to create metal droplets from donor metal micro wires, which droplets, when solidified in the aggregate, form 3D structures. A supply of metal micro wire is arranged so as to be fed towards a nozzle area by a piezo translator. Near the nozzle, an end portion of the metal micro wire is heated (e.g., by a laser pulse or an electric heater element), thereby causing the end portion of the metal micro wire near the nozzle area to form a droplet of metal. A receiving substrate is positioned to receive the droplet of metal jetted from the nozzle area.