Multi-Material Additive Manufacturing via Laser Parameter Control
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Solution Overview
Problem
Existing additive manufacturing techniques struggle to produce multi-material parts with complex shapes, specifically those comprising metal and dielectric portions in both the build plane and direction, which is crucial for applications like microwave engineering where precision is key.
Innovation Solution
A process using pre-treated metal powder with an oxidized and porous layer, allowing selective laser powder-bed fusion to convert regions into dielectric or densify them in metal form without changing powders, using adjustable laser parameters to achieve the desired energy densities and dwell times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing techniques are used to produce multi-material parts, then various materials can be deposited, but it requires changing powders or modifying devices which increases device complexity and process steps
Solution Approach 1:
The patent applies parameter changes by modifying laser parameters (power, speed, hatching distance) to transform a single metal powder material into different final materials (metal vs. ceramic) through controlled oxidation states. This eliminates the need for multiple powder materials or device modifications, resolving the contradiction between multi-material capability and device complexity
Solution Approach 2:
The patent applies preliminary action by pre-treating the metal powder with an oxidizing reagent before additive manufacturing to create a porous oxidized layer on the powder surface. This pre-treatment enables subsequent selective conversion to ceramic or metal phases during laser processing, allowing multi-material production without changing powders or devices
2Ease of manufacture
If binder jetting is used to manufacture multi-material parts, then composite parts can be formed, but additional inspection steps are required to detect binder shrinkage which reduces productivity
Solution Approach 1:
The patent applies the taking out principle by completely eliminating the binder material from the process. Instead of using binder jetting with organic binders that require removal and inspection, the invention uses direct laser fusion of pre-treated metal powder, removing the harmful binder step and associated inspection requirements, thus improving productivity while maintaining composite part formation capability
3Adaptability or versatility
If material jetting with photosensitive polymer is used, then multi-material parts can be produced, but the polymer matrix limits temperature resistance and microwave characteristics which reduces manufacturing precision for microwave applications
Solution Approach 1:
The patent applies parameter changes by controlling laser parameters and oxidation conditions to produce metal and ceramic phases with precise dimensional control. The resulting inorganic materials (metal and ceramic) provide superior temperature resistance and microwave characteristics compared to polymer-based methods, resolving the contradiction between multi-material production and manufacturing precision for microwave applications
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
Enables the production of multi-material parts with precise control over metal and dielectric regions, achieving the necessary precision for microwave applications without the need for multiple powders or device modifications.
Implementation Method 1
the parameters of application of the laser allow a first energy density to be applied to said first region and/or the laser beam to be kept for a first dwell time on said first region
Implementation Method 2
a step of melting by laser all or some of said layer of pre-treated metal powder
Implementation Method 3
a step of melting by laser all or some of said layer of pre-treated metal powder
Implementation Method 4
a step of providing a pre-treated metal powder comprising grains and an oxidized and porous layer on a surface of said grains
Data Source
AI summary
A process for manufacturing a multi-material part by additive manufacturing, includes the following steps: a) a step of providing a pre-treated metal powder comprising grains and an oxidized and porous layer on a surface of the grains; b) a selective laser powder-bed fusion step comprising implementation of steps i) and ii) as follows: i) a step of forming a layer from the pre-treated metal powder; ii) a step of melting by laser the layer, the melting step being carried out under a reactive atmosphere and comprising changing parameters of application of the laser so that at least a first region of the layer is converted so as to lower the electrical conductivity thereof, thus forming a dielectric, and so that at least a second region of the layer is densified without converting it, the at least a first region being formed when the parameters of application of the laser allow a first energy density to be applied to the first region and/or the laser beam to be kept for a first dwell time on the first region, the at least a second region being formed when the parameters of application of the laser allow a second energy density to be applied to the second region and/or the laser beam to be kept for a second dwell time on the second region, and the first energy density being higher than the second energy density and/or the first dwell time being longer than the second dwell time. A part obtained using the process is also provided.