Non-Uniform Porous AM Components With Dense-Bonded Regions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing methods lack the ability to introduce controlled porosity into parts, particularly for aerospace applications requiring specific porosity profiles for gas and fluid flow or acoustic dampening, and existing CAD-based approaches overwhelm processing capabilities.
Innovation Solution
A method and system for additive manufacturing that determines and programs a non-uniform porosity profile by adjusting energy source settings and build profiles, allowing for the creation of porous and dense regions with a full penetration mechanically bonded interface, enabling the production of parts with complex porosity patterns without secondary processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to create parts with controlled porosity for aerospace applications, then the functionality for gas and fluid flow or acoustic dampening is improved, but the manufacturing complexity and process control difficulty increase
Solution Approach 1:
The patent applies parameter changes by systematically varying laser power, scan speed, and hatch spacing parameters during additive manufacturing to control porosity levels. By adjusting these process parameters, the method creates regions with different porosity (from fully dense to highly porous) within the same part, enabling functional customization for gas flow, fluid filtration, or acoustic dampening applications without increasing manufacturing process complexity
Solution Approach 2:
The patent implements local quality by creating spatially varying porosity distributions within a single part. Different regions of the part can have tailored porosity characteristics - for example, highly porous regions for filtration or acoustic dampening, and dense regions for structural support. This localized property variation is achieved through programmed variations in laser processing parameters during the additive manufacturing process
2Strength
If traditional additive manufacturing methods are used to sinter or melt layers to remove porosity, then fully dense parts are achieved, but the ability to introduce controlled porosity is lost
Solution Approach 1:
The patent applies partial action by intentionally under-sintering or partially melting powder layers in specific regions during additive manufacturing. Instead of applying sufficient energy to completely densify the material, the method uses controlled partial sintering to retain desired porosity levels. This partial densification approach enables the creation of porous regions with controlled void fractions while maintaining adequate bonding between layers
Solution Approach 2:
The patent implements periodic action through oscillating or pulsing laser parameters during the sintering process. By periodically varying laser power or scan patterns, the method creates rhythmic heating and cooling cycles that control pore formation and consolidation. This periodic energy input allows precise control over the degree of densification, enabling alternating regions of dense and porous material
3Manufacturing precision
If CAD files are modified to model porosity, then porosity can be defined, but the file complexity overwhelms processing capabilities
Solution Approach 1:
The patent replaces the mechanical/CAD-based approach to porosity definition with a process-parameter-based system. Instead of modeling complex porous geometries in CAD files, the method uses software to control laser processing parameters (power, speed, hatch spacing) that directly determine porosity during manufacturing. This substitution of geometric modeling with process control dramatically reduces file complexity and processing requirements while maintaining precise porosity definition
4Adaptability or versatility
If porous regions are created in additive manufactured parts, then fluid flow and acoustic dampening are improved, but mechanical strength decreases
Solution Approach 1:
The patent applies local quality by creating spatially differentiated regions within the part - highly porous zones for fluid flow or acoustic dampening, and dense zones for structural strength. The transition between these regions is carefully controlled through gradient variations in laser parameters, ensuring that porous regions providing fluid flow capability are strategically located where mechanical loads are minimal, while dense regions provide structural support
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 economic production of parts with tailored porosity for specific technical applications, such as rocket engine components, by integrating porous and fully dense regions within the same part, enhancing mechanical strength and fluid flow characteristics.
Implementation Method 1
applying an energy source such as a laser or an electron beam across the layer of powder to sinter or melt the powder
Implementation Method 2
melt the powder exposed to the energy
Implementation Method 3
sinter or melt the powder exposed to the energy and at least partially bind the powder with prior layers and adjacent areas
Data Source
AI summary
An additively manufactured non-uniform porous material in-situ with dense material for the in situ additive manufacturing of both porous and dense material in the same part so that no secondary process is required. The additively manufactured non-uniform porous material in-situ with dense material generally includes additively manufactured porous material which can be tuned for porosity and density, has the ability to be built in situ with dense material, and can also be tuned for response to pressure waves. Also included are computer program products, methods and components and systems manufactured using the methods.