Selective Nanoparticle Reshaping in 3D Articles
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Solution Overview
Problem
Current processes for producing three-dimensional articles with nanoparticles, such as optical filters and sensing elements, are limited by the need to reshape nanoparticles in the feedstock material rather than in the three-dimensional article itself, restricting the number of structures that can be created due to process controls and the inherent limitations of multiple feedstock additive manufacturing and stacking.
Innovation Solution
A process that reshapes nanoparticles within the three-dimensional article using photo-thermal processes combined with photo-chemistry, employing broadband non-coherent light sources for isovolumetric control, allowing for rapid and cost-effective manufacture of materials with tunable plasmonic properties, including opto-electronics and colorimetric sensors, by retaining nanoparticle volume and single crystallinity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nanoparticles are reshaped in the feedstock material before assembly, then the assembly process is simplified, but the number of structures that can be created is limited due to process controls and manufacturing constraints
Solution Approach 1:
The patent inverts the conventional approach by performing nanoparticle reshaping after assembly rather than before. The three-dimensional article is first assembled from nanoparticles, then the nanoparticles are selectively reshaped in the final structure. This inversion enables complex three-dimensional structures to be created while maintaining manufacturing simplicity, as the reshaping step occurs after the structural assembly is complete.
Solution Approach 2:
The patent applies preliminary action by pre-positioning nanoparticles in the feedstock material with specific orientations and arrangements before assembly. This preliminary configuration allows the nanoparticles to be easily assembled into three-dimensional structures, and subsequently reshaped in the final article to achieve desired optical properties, thereby resolving the contradiction between assembly simplicity and structural versatility.
2Adaptability or versatility
If multiple feedstock additive manufacturing is used to create three-dimensional articles, then various structures can be produced, but the process is limited to a small number of feedstocks and stacking operations
Solution Approach 1:
The patent applies universality by using a single feedstock material containing nanoparticles that can be assembled into various three-dimensional structures. The same feedstock and assembly process can create different structural configurations, and the nanoparticles can be subsequently reshaped to achieve different optical properties. This eliminates the need for multiple feedstocks and complex stacking operations, reducing process complexity while maintaining structural versatility.
Solution Approach 2:
The patent utilizes parameter changes by selectively reshaping nanoparticles in different regions of the three-dimensional article to achieve desired optical properties. By controlling the reshaping parameters (such as light intensity, duration, and spatial distribution), the same structural platform can be tuned for different applications, including optical filters, sensing elements, and other photonic devices, thereby achieving versatility without increasing process complexity.
3Manufacturing precision
If nanoparticles are reshaped in the three-dimensional article itself, then each nanoparticle can be selectively shaped for superior performance, but the reshaping process requires precise control and additional processing steps
Solution Approach 1:
The patent applies local quality by selectively reshaping nanoparticles in specific regions of the three-dimensional article based on the desired optical properties for each location. Different regions can be treated with different reshaping conditions (light intensity, duration, wavelength) to achieve locally optimized nanoparticle shapes and optical characteristics. This localized approach enables superior performance in each region while maintaining overall manufacturing efficiency through parallel processing of multiple regions.
Solution Approach 2:
The patent replaces mechanical reshaping methods with optical or thermal fields to selectively reshape nanoparticles. By using light sources (such as lasers or LED arrays) or thermal energy, nanoparticles can be reshaped without mechanical contact, enabling precise control over nanoparticle shape and size. This substitution of mechanical systems with field-based methods improves manufacturing precision while maintaining productivity through non-contact, parallel processing capabilities.
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 three-dimensional articles with superior performance and tunable properties, such as selective electromagnetic radiation absorption, through faster and more controlled reshaping of nanoparticles, overcoming the limitations of traditional methods.
Implementation Method 1
A process that reshapes nanoparticles within the three-dimensional article using photo-thermal processes combined with photo-chemistry, employing broadband non-coherent light sources
Implementation Method 2
A process that reshapes nanoparticles within the three-dimensional article using photo-thermal processes combined with photo-chemistry
Data Source
AI summary
The present invention relates to processes for selective reshaping of nanoparticles in three dimensional articles, three dimensional articles produced by such processes, and methods of using such three dimensional articles. As a result of the aforementioned process, such three dimensional articles can have selective tuning that arises, at least in part, from the reshaped nanoparticles found in such articles. Such tuning provides the aforementioned articles with superior performance that can be advantageous in the areas including such as optical filters, multi-functional composites and sensing elements.