Ultrasonic 3D Printing via Phased Array Transducers
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Solution Overview
Problem
Current 3D body shaping methods in additive manufacturing require significant energy expenditure and time, especially when using layering processes, which can be inefficient for producing high-quality 3D bodies.
Innovation Solution
The method involves arranging fusible or curable material in a matrix space and using ultrasonic waves from multiple transducers to fuse or harden the material at defined matrix points, with a phased array arrangement for focused energy application, allowing for rapid shaping without moving the material or transducers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layering processes are used for additive manufacturing, then 3D bodies can be formed by adding material, but the process requires significant energy expenditure and time
Solution Approach 1:
The patent replaces mechanical layering processes with ultrasonic wave-based material deposition. Instead of mechanically adding and shaping material layer by layer, ultrasonic waves are used to fuse material particles directly at defined matrix points in 3D space, eliminating the need for sequential layer construction and significantly reducing both time and energy requirements
Solution Approach 2:
The invention transitions from 2D layer-by-layer construction to 3D volumetric manufacturing. Material is deposited and fused directly at spatial coordinates (x, y, z) within the build volume, allowing simultaneous construction throughout the 3D space rather than sequential layer formation, thereby dramatically improving productivity
2Productivity
If layering processes are used for additive manufacturing, then 3D bodies can be formed by adding material, but the process requires significant time
Solution Approach 1:
The patent implements continuous material deposition and fusion through ultrasonic waves. Material is continuously supplied to the build zone and fused at each matrix point without interruption, eliminating the cyclical stop-start nature of layer-by-layer processes where the build head must repeatedly position, deposit, and move to the next layer
Solution Approach 2:
By enabling direct 3D material placement at any (x, y, z) coordinate, the system eliminates the sequential Z-axis layer progression constraint. Multiple material points can be processed simultaneously across the build volume, reducing total build time proportionally to the degree of parallelization achieved
3Productivity
If ultrasonic waves are focused at matrix points from outside the matrix space, then production is accelerated, but precise positioning and sequencing is required
Solution Approach 1:
The patent employs dynamic focusing of ultrasonic waves where the focal point can be electronically steered to any matrix point coordinate. The system dynamically adjusts the phase and amplitude of ultrasonic waves from multiple transducers to concentrate energy precisely at the target (x, y, z) position, enabling rapid repositioning without mechanical movement of the transducer array
Solution Approach 2:
The control system incorporates feedback mechanisms to monitor and adjust ultrasonic wave parameters in real-time. By detecting the actual material fusion state and position, the system dynamically optimizes the ultrasonic energy delivery, ensuring precise material deposition while adapting to variations in material properties or positioning errors
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 significantly accelerates the production of high-quality 3D bodies by minimizing energy use and time, achieving precise shaping with reduced susceptibility to errors and eliminating the need for support structures or inert gases, while allowing for the integration of additional components like electronics.
Implementation Method 1
applying superimposed and at least partially to the hardenable material at the matrix points ultrasonic waves sequentially directed at the matrix points for curing the curable material and primary shaping of the 3D body
Implementation Method 2
The impact temperature is in particular below a melting or sintering temperature of the fusible material
Data Source
Figure 1a~1d
Figure 2a~2c
Figure 3
AI summary
The present invention relates to a method for the primary forming of a 3D body (7) from a fusable and/or hardenable material (4), comprising the following steps, in particular in the following sequence: - arrangement of the fusable and/or hardenable material (4) in a matrix space (2) with a matrix consisting of X-coordinates, Y-coordinates and Z-coordinates; - determining matrix points (5) in the matrix space (2), which define the 3D body (7) and have respectively a X-coordinate, a Y-coordinate and a Z-coordinate; - subjecting the fusable and/or hardenable material (4) at the matrix points (5) to superimposed ultrasonic waves from at least two ultrasonic emitters (3.1, 3.2 to 3.n), which are at least partially directed sequentially to the matrix points (5), for fusing and/or hardening the pulverulent material (4) and the primary forming of the 3D body (7). The invention further relates to a device for the primary forming of a 3D body (7) from a fusable and/or hardenable material (4), comprising: - a housing (1) defining a matrix space (2) with a matrix consisting of X-coordinates, Y-coordinates and Z-coordinates for receiving the fusable and/or hardenable material (4); - a control device for determining matrix points (5) in the matrix space (2), which define the 3D body (7) and have respectively a X-coordinate, a Y-coordinate and a Z-coordinate; - at least two ultrasonic emitters (3.1, 3.2 to 3.n) for subjecting the fusable and/or hardenable material at the matrix points (5) to superimposed ultrasonic waves which are at least partially directed sequentially to the matrix points, for fusing and/or hardening the fusable and/or hardenable material and the primary shaping of the 3D-body (7) in the housing (1).