Targeted Heating for Liquid Metal Jet Additive Manufacturing
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Solution Overview
Problem
Conventional liquid metal jet printing systems face issues with inconsistencies in build strength, adhesion, porosity, surface finish, cracking, and fractures due to inadequate temperature control during the printing process, leading to the need for costly secondary processes to correct these defects.
Innovation Solution
The implementation of a targeted heating system that controls the temperature and temperature gradient of molten metal droplets as they are deposited on a substrate, using lasers to heat the droplets and substrate, thereby modifying interfacial temperatures and improving the mechanical properties of the printed articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional liquid metal jet printing is used without targeted heating, then the printing process is simpler and faster, but the articles exhibit inconsistencies in build strength, adhesion, porosity, surface finish, cracking, and fractures
Solution Approach 1:
The heating function is segmented from the general printing system into a dedicated targeted heating system that operates independently. The heating system includes separate heating zones (first heating zone for the substrate, second heating zone for the droplet flight path) that can be controlled independently to address specific thermal requirements at different locations in the printing process.
Solution Approach 2:
The patent applies local quality by providing targeted heating at specific locations rather than uniform heating throughout the system. The first heating zone heats the substrate locally where droplets will be deposited, and the second heating zone heats the droplets locally during their flight path. This localized thermal control allows precise temperature management at critical interfaces without affecting the entire system.
2Manufacturing precision
If post-printing processes such as machining and finishing are implemented to correct defects, then article quality improves, but productivity decreases and cost increases
Solution Approach 1:
The targeted heating system performs preliminary thermal preparation before droplet deposition. By pre-heating the substrate in the first heating zone and heating droplets in the second heating zone during their flight path, the system ensures optimal thermal conditions are already in place when droplets contact the substrate. This preliminary thermal control prevents defects from forming in the first place, eliminating the need for subsequent corrective machining and finishing operations.
3Strength
If temperature control of droplets in flight path is implemented, then adhesion and build strength improve, but energy consumption increases
Solution Approach 1:
The system dynamically adjusts heating parameters including temperature, heating duration, and power levels based on the specific printing requirements, material properties, and real-time process conditions. The controller modulates the heating zones to provide optimal thermal energy only when and where needed, rather than continuous heating, thereby improving adhesion and build strength while minimizing unnecessary energy consumption.
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 enhances build strength, adhesion, and surface finish while reducing the need for post-printing processes, improving the overall quality and reducing production costs by maintaining precise thermal control during the printing process.
Implementation Method 1
The printhead may be configured to heat a build material to a molten build material and deposit the molten build material on the substrate in the form of droplets
Implementation Method 2
The targeted heating system may be configured to control a temperature or temperature gradient of the droplets in a flight path interposed between the printhead and the substrate. The targeted heating system may include one or more lasers
Implementation Method 3
As the metal drops contact the substrate, the metal drops cool to form the article
Data Source
AI summary
Additive manufacturing devices and methods for the same are provided. The additive manufacturing device may include a stage configured to support a substrate, a printhead disposed above the stage, and a targeted heating system disposed proximal the printhead. The printhead may be configured to heat a build material to a molten build material and deposit the molten build material on the substrate in the form of droplets to fabricate the article. The targeted heating system may be configured to control a temperature or temperature gradient of the droplets in a flight path interposed between the printhead and the substrate.