How to Precisely Control Solid-State 3D Printing for Stronger Materials

This patent describes a system for precisely controlling solid-state additive manufacturing, allowing real-time adjustments to create specific material structures without melting, using continuous material feeds.

What it covers

The patent describes a system for controlling solid-state additive manufacturing, a type of 3D printing that joins materials without melting them. The system uses a feeding mechanism to supply solid material (like wire, powder, or pellets, as in claims 25-30) to a tool. This tool then prints the material onto a workpiece while applying a downward force, causing the material to "plasticly deform" (claim 24). A controller monitors and adjusts process variables, such as the downward force (using measurements like interface temperature or tooling torque, claims 32-33) and filler flow rate (claim 31). This precise control allows the system to create specific internal structures, like honeycomb or sandwich patterns (claim 36), within the printed material. For example, an engineer could program the system to build a part with a specific internal strength by continuously adjusting the pressure and material flow based on real-time sensor data.

What it doesn't cover

• —Additive manufacturing processes that involve melting the filler material (e.g., traditional FDM, laser powder bed fusion).
• —Systems that do not continuously feed solid filler material to the tooling.
• —Control systems that do not specifically adjust downward force based on a measured process variable from the tooling.
• —Systems that do not aim to control the "microstructure" of the printed material.
• —Additive manufacturing where the material is not "plasticly deformed" during printing.

The clever bit

The novelty lies in the real-time, closed-loop control system that precisely adjusts multiple process variables, like downward force and material flow, to achieve a specific internal microstructure in solid-state additive manufacturing. This allows for fine-tuning material properties during the build process, rather than relying on pre-set parameters.

Why it matters

Precisely controlling the printing process in solid-state additive manufacturing is crucial for creating parts with desired strength and properties. This technology can produce complex geometries and join dissimilar materials, which is valuable for industries needing high-performance components. The ability to control microstructure in real-time can lead to more reliable and optimized parts.

Real-world examples

• 1.MELD Manufacturing's solid-state additive manufacturing machines
• 2.Repairing large metal components
• 3.Building lightweight aerospace structures
• 4.Creating custom industrial tooling
• 5.Manufacturing parts from difficult-to-weld alloys