Multi-chemistry microlattice structures via segmented photopolymerization
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Solution Overview
Problem
Existing methods for manufacturing microlattice structures are limited to single-chemistry structures, which restrict customization and functionality, and are inefficient for producing multi-chemistry structures, leading to challenges in creating complex mechanical applications with varied properties.
Innovation Solution
The development of multi-chemistry microlattice structures using a method that involves irradiating different photo-monomers with collimated light beams through distinct photomasks to form layers of polymers with varying chemistries, allowing for seamless integration of multiple chemistries and architectures in a three-dimensional structure, enabling the creation of structures with specific properties such as energy absorption and surface tuning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If typical manufacturing methods are used for single-chemistry microlattice structures, then manufacturing simplicity is maintained, but customization and functionality are limited
Solution Approach 1:
The manufacturing process is segmented into distinct stages: first forming a sacrificial microlattice structure from a first photo-monomer, then selectively removing portions with an etchant, and finally forming a second polymer structure in the removed regions. This segmentation enables multi-chemistry functionality while maintaining process manageability through clear separation of steps.
Solution Approach 2:
A sacrificial microlattice structure is formed in advance using a first photo-monomer before the final multi-chemistry structure is complete. This preliminary structure serves as a template that guides subsequent etching and polymer formation steps, enabling precise spatial control over where different chemistries will be located in the final product.
2Productivity
If typical manufacturing methods are used for single-chemistry microlattice structures, then process efficiency is maintained, but production of multi-chemistry structures becomes inefficient
Solution Approach 1:
The patent replaces traditional mechanical assembly methods with a photochemical approach. Collimated light beams are used to selectively polymerize photo-monomers in specific regions, and chemical etchants are used to selectively remove sacrificial material. This substitution enables efficient multi-chemistry structure formation without complex mechanical manipulation of multiple materials.
Solution Approach 2:
The manufacturing process exploits parameter changes in the photo-monomer system: the first photo-monomer is polymerized and then selectively removed by etching, changing the physical and chemical parameters of those regions to enable subsequent infiltration by the second photo-monomer. This parameter transformation enables efficient creation of multi-chemistry regions.
3Adaptability or versatility
If single-chemistry structures are manufactured, then structural uniformity is achieved, but functional versatility is restricted
Solution Approach 1:
The patent applies local quality by creating regions with different polymer chemistries in specific locations within the microlattice structure. The first polymer is formed in certain regions while the second polymer is formed in other regions, allowing each region to have properties optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
The final microlattice structure is a composite of at least two different polymer materials, each with distinct chemical and physical properties. This composite structure combines the benefits of different polymers (such as varying mechanical properties, chemical resistance, or optical characteristics) within a single integrated lattice architecture.
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 enables the production of multi-chemistry microlattice structures with enhanced customization and functionality, allowing for tailored mechanical properties and efficient manufacturing processes, suitable for applications like energy absorption and selective chemical reactions.
Implementation Method 1
irradiating a first photo-monomer with a plurality of collimated light beams to form a first polymer structure; and irradiating a second photo-monomer different than the first photo-monomer with a plurality of collimated light beams to form a second polymer structure
Data Source
AI summary
A multi-chemistry structure includes: a plurality of interconnected polymer struts arranged in a lattice; a first layer of the lattice including a first array of first unit cells; a second layer of the lattice including a second array of second unit cells; at least one region of the lattice being formed of a first polymer; and at least one region of the lattice being formed of a second polymer different from the first polymer.