# 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. - **Patent:** US 20240109245 - **Original title:** Process control systems and methods using a solid-state additive manufacturing system and continuous feeding systems and structures - **Owner:** Meld Manufacturing - **Status:** Active - **Times cited:** 9 - **Field:** manufacturing, mechanical, materials, aerospace, automotive, energy ## What it does 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 does NOT 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. ## 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 ## 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. ## Frequently asked questions ### What does How to Precisely Control Solid-State 3D Printing for Stronger Materials cover? 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. ### Who owns patent US 20240109245? This patent is owned by Meld Manufacturing. ### When does this patent expire? This patent is expected to expire on May 8, 2043, when the invention enters the public domain. ### What is patent US 20240109245 cited by? This patent has been cited by 9 later patents that build on its ideas. ### What problem does this patent solve? 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. ### What does this patent NOT cover? Additive manufacturing processes that involve melting the filler material (e.g., traditional FDM, laser powder bed fusion). **Full plain-English explainer:** https://patentbrief.org/patent/us/20240109245/process-control-systems-and-methods-using-a-solid-state-additive-manufacturing-s **Original patent:** https://patents.google.com/patent/US20240109245 --- _Source: PatentBrief — https://patentbrief.org. Patent facts are from public records; the plain-English explanation is PatentBrief's._ ## Related patents Semantically similar inventions in the PatentBrief corpus: - [Building Metal Parts Without Melting: Solid-State 3D Printing System](https://patentbrief.org/patent/us/11311959/solid-state-additive-manufacturing-system-and-material-compositions-and-structur) — This patent describes a system for building or repairing metal parts by frictionally heating and stirring materials together without melting them, precisely controlling the material's internal structure as it's made. - [How to Improve 3D Printing Using Cold Spray Metal Deposition](https://patentbrief.org/patent/us/12233456/mars-colonial-transporter-architecture) — A method for perfecting metal 3D printing by analyzing how spray angles affect material quality and adjusting the printer's path to fix errors. - [How Boeing 3D Prints Strong Lightweight Spacecraft Panels](https://patentbrief.org/patent/us/11794927/starship-life-support-system) — A method for printing a single-piece, high-strength spacecraft panel using 3D printing to create complex internal trusses that eliminate the need for bolts or welds. - [How Machines Build 3D Objects Layer by Layer from Melting Plastic](https://patentbrief.org/patent/us/5121329/fdm-3d-printing-stratasys) — This patent describes a method and machine for creating three-dimensional objects by precisely depositing melted material, layer by layer, from a movable nozzle onto a base. - [How to 3D Print Metal Parts with Easy-to-Remove Supports](https://patentbrief.org/patent/us/12358049/interface-layers-for-removable-supports) — This patent describes a method for 3D printing complex metal objects with support structures that can be easily removed after the final part is made solid, by using a special non-stick layer in between.