Additive Manufacturing Susceptor Removal in Oxygen Atmosphere

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Solution Overview

Problem

Current additive manufacturing devices face limitations in sintering processes due to the reaction of susceptors with oxygen at elevated temperatures, restricting the production of a broader range of objects in a cost-effective manner, especially when using electromagnetic radiation.

Innovation Solution

The method involves depositing a layer of powdered build material and selectively applying a liquid containing a susceptor and sintering aids in a stable dispersion, allowing sintering by microwave or radio frequency radiation in an atmosphere containing oxygen, which enables efficient heating and removal of susceptors that negatively impact mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If sintering is performed using electromagnetic radiation with susceptors, then heating efficiency is improved, but the susceptors react with oxygen at elevated temperatures causing harmful effects

Engineering Contradiction:

Improveheating efficiencyVSAvoidreaction with oxygen

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and removes the harmful susceptor materials from the final sintered object through selective dissolution or decomposition processes, eliminating their harmful reaction with oxygen while preserving their useful heating function during the sintering process

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the harmful reaction between susceptors and oxygen into a beneficial process by controlling the atmosphere and timing to allow selective oxidation or reaction that removes the susceptor materials after they have served their heating purpose, thereby transforming a harmful interaction into a useful material removal mechanism

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If sintering is performed in an oxygen-free environment to prevent susceptor reaction, then harmful reactions are avoided, but the complexity and cost of the manufacturing process increases

Engineering Contradiction:

Improvesusceptor reaction preventionVSAvoidatmosphere control system

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent performs preliminary sintering in a controlled atmosphere to activate and heat the object using susceptors, then subsequently removes the susceptors through selective dissolution or decomposition in a second processing step, eliminating the need for continuous oxygen-free environment maintenance

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent maintains continuous useful action by seamlessly transitioning from the sintering phase with susceptors to the susceptor removal phase, ensuring that the object progresses through processing stages without interruption while the atmosphere conditions are adjusted to match each stage's requirements

Inventive Principle:

Principle #20Continuity of useful action

3Object-affected harmful factors

If traditional sintering methods are used without susceptors, then oxygen reaction issues are avoided, but the productivity and heating speed decrease

Engineering Contradiction:

Improveoxygen reaction avoidanceVSAvoidsintering speed

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent uses susceptors as intermediary materials that enable rapid heating during sintering through electromagnetic radiation absorption, then removes these intermediaries through selective dissolution or decomposition, thereby achieving high productivity without the permanent presence of harmful materials that would react with oxygen

Inventive Principle:

Principle #24Intermediary (Mediator)

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 allows for the cost-effective production of high-quality three-dimensional objects with improved structural and mechanical properties by enabling sintering in an oxygen-rich environment, expanding the range of producible objects and enhancing efficiency.

Implementation Method 1

heating the object by electromagnetic radiation with a microwave or radio wave frequency to a temperature sufficient to sinter the powdered build material

Methodology Applied

Scientific EffectElectromagnetic radiation absorption and conversion to thermal energy: Dielectric Heating

Implementation Method 2

heating the object by electromagnetic radiation with a microwave or radio wave frequency

Methodology Applied

Scientific EffectMicrowave heating: Microwave Radiation

Implementation Method 3

heating the object by electromagnetic radiation with a microwave or radio wave frequency to a temperature sufficient to sinter the powdered build material

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 4

heating the object by electromagnetic radiation with a microwave or radio wave frequency to a temperature sufficient to sinter the powdered build material

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11260556B2Additive manufacturing in an atmosphere including oxygen

Publication Date: 2022.03.01 PERIDOT PRINT LLC

AI summary

A method for additive manufacturing includes: forming a three-dimensional object by: depositing a layer of a powdered build material onto a surface; selectively depositing a liquid comprising a susceptor onto the layer of the powdered build material in a pattern; and heating the object by electromagnetic radiation with a microwave or radio wave frequency, in an atmosphere including oxygen, to a temperature sufficient to sinter the powdered build material.