Optical Growth of Trussed Structures Without Shadowing Limits
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Solution Overview
Problem
Existing technologies face challenges in forming large-scale trussed structures due to mechanical instability and shadowing issues during member growth, particularly with difficult-to-machine materials like ceramics and refractories, limiting the achievable footprint and throughput.
Innovation Solution
A method and system utilizing a spatial light modulator to simultaneously grow multiple members of a trussed skeleton, enabling large-scale formation of interconnected structures with controlled deposition of materials like refractories and ceramics, using laser-assisted chemical vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to form large-scale trussed structures, then mechanical stability and shadowing issues occur during member growth, but achieving large footprint and high throughput is limited
Solution Approach 1:
The patent segments the trussed structure into multiple independent members that are grown simultaneously rather than sequentially. Each member is formed as a separate element using independent optical hot spots, allowing parallel fabrication without mechanical interference. This segmentation enables large-scale structures to be built with high throughput while maintaining mechanical stability through controlled, simultaneous growth of all members.
Solution Approach 2:
The patent replaces mechanical assembly methods with optical-based additive manufacturing. Instead of physically assembling pre-formed members (which causes shadowing and mechanical instability), the system uses optical fields to directly deposit material and form members in place. This substitution of mechanical processes with optical processes eliminates shadowing issues and improves both throughput and reliability.
2Area of stationary object
If conventional additive manufacturing is used, then mechanical stability is maintained, but shadowing issues limit the achievable footprint and throughput
Solution Approach 1:
By segmenting the structure into multiple members formed by independent optical hot spots, the system can simultaneously grow multiple members across a large footprint. This parallel formation approach removes the shadowing limitation that would otherwise constrain the achievable area, while maintaining high throughput through simultaneous fabrication of all members.
Solution Approach 2:
The patent transitions from sequential layer-by-layer fabrication to simultaneous three-dimensional formation of multiple members. By using optical fields that can target multiple spatial locations at once, the system achieves large footprint structures with high throughput, overcoming the dimensional constraints of conventional additive manufacturing.
3Strength
If difficult-to-machine materials like ceramics and refractories are used, then material properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces mechanical machining of difficult-to-machine materials with optical-based additive manufacturing. By using optical fields to directly deposit and form ceramic and refractory members, the system eliminates the need for complex mechanical processing. This approach maintains the superior material properties of ceramics and refractories while dramatically reducing manufacturing complexity and cost.
Solution Approach 2:
The patent changes the manufacturing parameters from mechanical cutting and shaping to optical deposition and in-situ formation. This parameter change enables the use of difficult-to-machine materials like ceramics and refractories without incurring high machining costs or complexity, as the optical process directly forms the final structure without requiring subsequent mechanical processing.
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 low-cost, high-throughput manufacturing of large trussed structures with improved mechanical stability and uniformity, allowing for larger footprints and complex geometries that conventional methods cannot achieve.
Implementation Method 1
a laser beam is focused onto a substrate to locally heat the substrate and deposited material
Implementation Method 2
focusing the plurality of individual laser beams onto a focal plane initially substantially coincident with a broad face of a substrate to produce a plurality of individual focused laser spots
Implementation Method 3
material derived from the gaseous deposition precursor deposits within a locally heated region proximal the plurality of individual focused laser spots to form deposited material
Data Source
AI summary
A method for forming a skeleton (e.g., space frame, trussed structure, regular foam, open-cell foam, closed cell foam, etc.) can include providing instructions for spatial locations of optical hot spots, generating the optical hot spots, and growing material at the optical hot spots to form the skeleton. The method can optionally include shaping the grown material and/or infilling the skeleton.