Selective Laser Sintering Grid for Mammography
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of large footprint grids for mammography applications with small thickness poses challenges in separating them from a metal carrier and handling, leading to material losses and increased costs.
Innovation Solution
A method involving a support element made of X-ray transparent material with a self-supporting metal layer for selective laser sintering, allowing the grid to be manufactured with reduced material loss and improved handling, where the support element remains attached during application, simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal carrier is used to support the grid during manufacturing, then the grid can be produced with selective laser sintering, but the grid cannot be easily separated from the carrier and material losses occur
Solution Approach 1:
A support element made of X-ray transparent material serves as an intermediary carrier during the selective laser sintering process. This support element can be easily removed after manufacturing without causing material losses, as it does not interfere with the X-ray transmission properties of the final grid product.
Solution Approach 2:
The support element is designed to be completely removable from the final grid structure. After the grid is manufactured using selective laser sintering on the support element, the support element is extracted and removed, leaving only the grid structure without any residual material losses.
2Use of energy by moving object
If the grid thickness is reduced to meet mammography requirements, then radiation transmission is improved, but the grid becomes difficult to handle and separate from the carrier
Solution Approach 1:
The X-ray transparent support element acts as a mediator that provides mechanical support during manufacturing and handling. Since the support element is made of X-ray transparent material, it does not interfere with radiation transmission, yet it provides the necessary structural support for handling the thin grid during the manufacturing process.
Solution Approach 2:
The support element is provided in advance during the manufacturing process to enable proper positioning and handling of the thin grid structure. This preliminary support allows the grid to be manufactured and handled correctly before the support element is removed, ensuring proper handling without compromising the thin grid structure.
3Area of stationary object
If a large footprint grid is manufactured for mammography, then the grid can cover the required detection area, but the grid becomes difficult to separate from the carrier and handling becomes problematic
Solution Approach 1:
The support element serves as an intermediary carrier that enables the manufacturing and handling of large footprint grids. The support element provides the necessary mechanical strength and handling capability for large grids while being made of X-ray transparent material to not interfere with radiation transmission through the grid.
Solution Approach 2:
The support element performs multiple functions: it serves as a carrier during manufacturing, provides mechanical support for handling, and can be removed without affecting the grid's radiation transmission properties. This multi-functionality solves the handling problems associated with large footprint grids.
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
The method enables the production of grids with reduced material loss and improved handling, resulting in lower production costs and higher reliability, specifically adapted for mammography applications with enhanced radiation transmission properties.
Implementation Method 1
building a selective transmission structure at a surface of the metal layer with a material which absorbs electromagnetic radiation to be selectively transmitted through the grid, wherein the transmission structure is built using selective laser sintering
Implementation Method 2
building a selective transmission structure at a surface of the metal layer with a material which absorbs electromagnetic radiation to be selectively transmitted through the grid, wherein the transmission structure is built using selective laser sintering
Implementation Method 3
providing a support element having self-supporting stability, wherein the support element is made with a material which essentially absorbs no electromagnetic radiation to be selectively transmitted through the grid
Implementation Method 4
building a selective transmission structure at a surface of the metal layer with a material which absorbs electromagnetic radiation to be selectively transmitted through the grid
Data Source
AI summary
A method of manufacturing a grid (1) for selective transmission of electromagnetic radiation, particularly X-ray radiation, is proposed. The method comprises: providing a support element (3) having self-supporting stability, wherein the support element (3) is made with a material which essentially absorbs no electromagnetic radiation to be selectively transmitted through the grid; applying a metal layer (5) at a surface of the support element (3); and building a selective transmission structure (7) at a surface of the metal layer (5) with a material which absorbs electromagnetic radiation to be selectively transmitted through the grid, wherein the transmission structure is build using selective laser sintering. As the support element (3) provides sufficient mechanical stability but does not absorb the respective radiation, the selective transmission structure (7) build thereon using selective sintering might not have to be subsequently separated from a manufacturing substrate thereby preventing separation/dicing losses and, furthermore, might be structurally held and protected against damage during handling of the grid.