Additive Trussed Structures Using Optical Growth to Prevent Breakage

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Solution Overview

Problem

Existing methods struggle to form large-scale trussed structures without member breakage and efficiently produce materials like refractories and ceramics with complex geometries.

Innovation Solution

A system and method utilizing optical-based material manufacturing, specifically through a spatial light modulator to simultaneously grow interconnected trussed skeletons, enabling large-scale formation and low-cost production of materials with anisotropic properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional manufacturing methods are used to form large-scale trussed structures, then production cost and time are reduced, but member breakage occurs and structural integrity deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces conventional mechanical manufacturing methods with optical-based material manufacturing. A laser beam is used to selectively vaporize and deposit material, forming trussed structures layer by layer without mechanical contact. This substitution eliminates member breakage during formation while enabling large-scale production through automated layer-by-layer construction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent forms trussed structures through sequential layer-by-layer construction, where each layer is built independently and then stacked to form the complete structure. This segmentation allows each layer to be manufactured without stress from subsequent layers, preventing member breakage while maintaining high production efficiency through continuous automated processing.

Inventive Principle:

Principle #1Segmentation

2Reliability

If optical-based material manufacturing is used to form large-scale trussed structures, then member breakage is prevented and structural integrity is improved, but production time and complexity increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a multifunctional manufacturing system where a single laser-based apparatus performs multiple operations: it heats material, vaporizes it, deposits it layer by layer, and forms complex three-dimensional trussed structures. This universal system consolidates what would otherwise require multiple specialized manufacturing processes, reducing overall system complexity despite the advanced optical technology used.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If optical-based material manufacturing is used to form large-scale trussed structures, then structural integrity and anisotropic properties are improved, but production cost increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent controls the laser parameters (power, duration, focal position) to precisely regulate material deposition. By adjusting these parameters, the system optimizes material usage efficiency and structural quality, reducing waste and enabling cost-effective production of high-integrity trussed structures with controlled anisotropic properties.

Inventive Principle:

Principle #35Parameter changes

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 creation of large trussed structures with smooth surfaces and controlled anisotropic properties, facilitating the production of refractories and ceramics with enhanced mechanical stability and scalability.

Implementation Method 1

focusing a plurality of individual laser spots on a focal plane initially substantially coincident with a broad face of a substrate... material derived from the gaseous deposition precursor deposits within a locally heated region proximal the plurality of individual focused laser spots

Methodology Applied

Scientific EffectLaser heating: Laser

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

Methodology Applied

Scientific EffectOptical focusing: Focusing

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

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS20260014624A1Trussed structures for additive manufacturing and methods of formation thereof

Publication Date: 2026.01.15 ORCA SCIENCES LLC

AI summary

A refractory material foam can include a plurality of members made from a refractory material, where each member of the plurality of members is fused to one or more other members of the plurality of members at a fusion point, where each member of the plurality of members is arranged in a determined spatial location.