Additive Manufacturing Porogen Module for Heterogeneous Porous Structures
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Solution Overview
Problem
Conventional powder-based additive manufacturing faces limitations in achieving small internal features, in-situ control of micro- and macro-porosity, and heterogeneous material composition, making it difficult to produce structures with complex conformal channels and required porosity for industrial and biomedical applications.
Innovation Solution
A system and method for additive manufacturing that includes a porogen module for selectively dispensing removable porogens to control porosity, combined with a controller for precise layer formation and post-processing, allowing for the creation of heterogeneous porous structures with complex internal features and varying material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional powder-based additive manufacturing is used, then structures can be built with complex internal architecture, but the smallest achievable internal features are limited and porosity control is poor
Solution Approach 1:
The system segments the additive manufacturing process into distinct functional modules: powder feeding module, binder dispensing module, and porogen dispensing module. Each module independently controls a specific aspect of the process, enabling precise deposition of materials and porogens without interfering with other functions. This modular segmentation allows achieving small internal features while maintaining manageable system complexity through functional decomposition.
Solution Approach 2:
The patent introduces porogens as intermediary materials that are temporarily deposited within the green body structure. These porogens serve as placeholders that define the desired porosity and internal channel geometry. After sintering, the porogens are removed, leaving behind the desired porous structure. This intermediary approach enables precise porosity control without requiring direct manipulation of the final pore spaces during manufacturing.
2Adaptability or versatility
If a single powder material is used, then the process is simple, but the material composition and mechanical properties are homogeneous and cannot be varied
Solution Approach 1:
The system employs a universal powder feeding module that can handle multiple types of powder materials. The module is designed with interchangeable powder containers and a common dispensing mechanism that can accommodate different powder compositions, sizes, and properties. This multi-functional design enables the system to switch between different material compositions without requiring completely different hardware, thus achieving material versatility while controlling system complexity through a unified platform.
Solution Approach 2:
The patent utilizes composite material strategies by combining different powder materials in single or multiple layers. The system can deposit mixtures of powders with different properties (e.g., different metal powders, ceramic powders, or polymer powders) to create functionally graded or heterogeneous structures. This approach enables varied mechanical properties and material compositions within a single structure, achieving adaptability through material composition control.
3Manufacturing precision
If support materials or loose powder are embedded within inner cavities, then the structure can be built, but the internal features are difficult to control and clean
Solution Approach 1:
The system performs preliminary action by depositing porogens into the green body structure before sintering. These porogens are strategically placed to define the desired porosity and internal channel locations. By pre-positioning these removable elements, the system ensures that the final porous structure will have the exact desired geometry without requiring post-processing cleaning or intervention. This preliminary placement eliminates the problem of trapped support materials.
Solution Approach 2:
The patent employs the discarding principle by using temporary porogen materials that are intentionally designed to be removed after sintering. These porogens serve their purpose during manufacturing by defining the porous structure, then are discarded (removed) in a controlled manner after the structure is sintered. This approach transforms the problem of trapped support materials into a solution where temporary materials are systematically removed to reveal the desired internal features, making post-processing straightforward rather than difficult.
4Adaptability or versatility
If conventional methods are used, then the process is straightforward, but structures with conformal channels and required porosity cannot be produced
Solution Approach 1:
The system adds another dimension of control by incorporating the porogen dispensing module that operates independently from the powder and binder modules. This additional functional dimension enables the system to deposit porogens in three-dimensional space within the green body, creating complex internal channel networks and conformal geometries that cannot be achieved with conventional two-dimensional layer-by-layer powder deposition alone. The porogen module adds spatial versatility without fundamentally changing the core additive manufacturing approach.
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 structures with internal channels and porosities below 500 μm, heterogeneous material composition, and controlled mechanical properties, overcoming the limitations of conventional methods by selectively depositing porogens and controlling compaction forces, thus achieving complex geometries and functional properties.
Implementation Method 1
a pulsed laser dispensing module comprising: a pulsed laser; and a film of photopolymer; wherein the pulsed laser is configured to contact the photopolymer to produce at least one drip from the film of photopolymer
Implementation Method 2
the pulsed laser is configured to contact the photopolymer to produce at least one drip from the film of photopolymer
Implementation Method 3
the porogen module includes an electrostatic system and a pneumatic system; wherein the electrostatic system is configured to trap at least one porogen onto a charged plate
Implementation Method 4
the pneumatic system is configured to release the at least one porogen onto the powder material
Implementation Method 5
the porogen module includes a vacuum system and a pneumatic system; wherein the vacuum system is configured to trap at least one porogen using vacuum
Implementation Method 6
a binder module for dispensing powder binding material, wherein the binding material is for binding the layers of powder material
Implementation Method 7
a compaction module configured to compact at least one of the powder, the binder and the at least one porogen after depositing at least one layer
Data Source
AI summary
A system and method for additive manufacturing of heterogeneous porous structures, and structures made therefrom. The system includes: a powder feeding module for depositing layers of powder material; a binder module for dispensing powder binding material; a porogen module for selectively depositing at least one porogen to the layers of powder material, wherein the at least one porogen is removable to produce at least one predetermined porosity in the part; and a controller to control the powder feeding module, binder module and porogen module. The method includes: forming a layer by performing at least one of: applying a powder to a substrate; applying a binder to the powder; applying at least one porogen to the powder based on a predetermined pattern; and forming additional layers until a predetermined number of layers is reached, wherein at least one of the layers includes a porogen.