Skeleton Structure for Uniform Metal Deposition in Additive Fabrication
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Solution Overview
Problem
Current additive fabrication techniques for metallic materials are limited by high costs, poor performance, and safety concerns, particularly in post-processing methods like Direct Metal Laser Sintering and molten metal infiltration, which often result in incomplete metal deposition, especially in internal regions of parts.
Innovation Solution
The method involves creating a skeleton structure using additive fabrication and subsequent electroless deposition, allowing for uniform metallic material distribution throughout the part, including internal areas, using a lattice structure with varying cell sizes and shapes to control deposition and achieve high metallization percentages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Direct Metal Laser Sintering or molten metal infiltration is used for metallic material deposition, then metallic parts can be fabricated, but incomplete metal deposition occurs especially in internal regions and safety concerns arise
Solution Approach 1:
The patent introduces a skeleton structure as an intermediary framework that supports uniform metal deposition. This skeleton acts as a mediator between the deposition process and the final metallic part, enabling complete metallization by providing structural support and ensuring reagent access to internal regions, thereby resolving the incomplete deposition and safety issues of direct laser sintering methods
Solution Approach 2:
The patent performs preliminary fabrication of a skeleton structure using additive manufacturing before conducting the metal deposition process. This preliminary action creates a prepared framework that guides subsequent electroless deposition, ensuring uniform metal distribution and complete coverage including internal regions, thus preventing the incomplete deposition problems associated with direct metal sintering
2Quantity of substance
If traditional electroplating is used for metal deposition, then metallic coating can be applied, but uniform distribution throughout internal areas is not achieved
Solution Approach 1:
The patent employs a porous skeleton structure with lattice geometry that allows deposition reagents to penetrate and access internal regions. This porous framework enables uniform electroless metal deposition throughout the entire structure including internal areas, achieving complete metallization that traditional electroplating cannot accomplish
Solution Approach 2:
The patent divides the final metallic part into a skeleton framework and deposited metal components. This segmentation allows the skeleton to provide structural support and reagent pathways while the deposited metal forms the final functional material, enabling uniform distribution throughout internal regions that traditional monolithic electroplating fails to achieve
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
This approach enables efficient, accurate, and cost-effective additive fabrication of metallic parts with substantial metallic material properties, allowing for near-net shape parts that can be further modified for precise dimensions, while avoiding the limitations of traditional methods like electroplating.
Implementation Method 1
subsequent electroless deposition, allowing for uniform metallic material distribution throughout the part
Data Source
AI summary
According to some aspects, a method is provided of forming a metallic object via additive fabrication, the method comprising obtaining a geometric description of a first object with an exterior surface, generating a geometric description of a second object, the second object bounded by the exterior surface of the first object and having one or more voids, fabricating said second object via additive fabrication based on said geometric description of the second object, and depositing a metallic material onto said second object, wherein the metallic material is deposited into said voids of second object.