Skeleton-Lattice Composite Formation for Difficult Materials
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Solution Overview
Problem
Existing manufacturing methods struggle to efficiently produce materials with challenging properties, such as high hardness, high melting temperature, and brittleness, which are difficult to process using traditional machining techniques.
Innovation Solution
A method involving the use of a skeleton structure as a template for depositing materials, allowing for the formation of composite materials with near-net shapes that decouple the process of defining the shape from densification, using laser-controlled manufacturing processes to achieve low-cost, high-throughput production of materials like refractory metals and ceramics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional machining techniques are used to process materials with high hardness, high melting temperature, and brittleness, then the material properties are maintained, but the processing difficulty and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by forming a skeleton structure that defines the near-final shape of the component before material deposition. This pre-defined skeleton eliminates the need for extensive post-processing machining, allowing difficult-to-machine materials to be formed with minimal subsequent processing while maintaining their challenging properties
Solution Approach 2:
The patent changes the manufacturing approach from subtractive (machining) to additive (deposition on skeleton). By changing the fundamental process parameter from removal to addition of material, the patent enables production of complex geometries in difficult-to-machine materials without the constraints of traditional machining
2Stability of the object's composition
If traditional manufacturing methods are used to produce complex shapes, then material properties can be maintained, but production time and cost increase
Solution Approach 1:
The skeleton structure performs preliminary shaping action, creating the complex geometry framework before material deposition. This preliminary formation of the near-final shape dramatically reduces production time compared to traditional methods that would require multiple machining operations to achieve the same complex geometry
Solution Approach 2:
The patent creates a composite structure consisting of the skeleton framework and the deposited material. This composite approach allows the final component to achieve both complex shapes and desired material properties simultaneously, improving productivity without compromising material composition stability
3Manufacturing precision
If extensive machining is performed on difficult-to-machine materials, then precise dimensions can be achieved, but material waste and processing cost increase
Solution Approach 1:
The skeleton structure is designed to match the near-final dimensions of the component, performing the shaping action before material deposition. This preliminary dimensional definition eliminates the need for extensive material removal, achieving precise dimensions with minimal material waste
Solution Approach 2:
The patent minimizes the need to discard material by forming the component through deposition on a pre-shaped skeleton. The skeleton itself can be reused or recovered, reducing overall material loss compared to traditional machining where significant material is removed and discarded
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 materials with improved properties, such as thermal conductivity and mechanical robustness, while maintaining cost-competitiveness and reducing the need for extensive machining, by leveraging a skeleton structure to facilitate deposition and densification.
Implementation Method 1
pyrolyzing a hydrocarbon feedstock to form pyrolyzed carbon, wherein the pyrolyzed carbon is formed at a plurality of hotspots generated using a set of laser beams
Implementation Method 2
depositing a refractory material onto the set of lattice members to form the near net-shape object, wherein depositing the refractory material comprises: heating the freestanding rigid lattice to a temperature between 200° C. and 3000° C.; and exposing the freestanding rigid lattice to a precursor fluid
Data Source
AI summary
A composite can include: a lattice comprising lattice material arranged at predetermined locations; and deposited material deposited on and around the lattice wherein the deposited material forms a unified material. A method for making a fabricated material can include: receiving a lattice, depositing material on the lattice, and optionally processing the fabricated material.