Spatial control of material properties in additive manufacturing

Patent metadata

Field	Value
Publication number	US-12377467-B2
Application number	US-202017310544-A
Country	US
Kind code	B2
Filing date	Apr 24, 2020
Priority date	Apr 30, 2019
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

In a general aspect, a method for additive manufacturing can include depositing a liquid on a first portion of an article, the liquid containing a dopant, the article including a feedstock material. The method can also include heating, at a first temperature, the article to, at least one of, evaporate or decompose the liquid. The heating at the first temperature can leave the dopant on the first portion of the article. The method can further include heating, at a second temperature, the article. The heating at the second temperature can result in the feedstock material melting and the dopant mixing with the feedstock material in a second portion of the article. The second portion of the article can include the first portion of the article.

First claim

What is claimed is:

1. A method for additive manufacturing, the method comprising:
depositing a liquid on a first portion of an article, the liquid including a dopant, the article including a feedstock material;
heating, at a first temperature, the article to, at least one of, evaporate or decompose the liquid, the heating at the first temperature leaving the dopant on the first portion of the article; and
after heating at the first temperature:
heating, at a second temperature different than the first temperature, the article, the heating at the second temperature resulting in a portion of the feedstock material melting and the dopant mixing with the portion of the feedstock material in a second portion of the article, the second portion of the article including the first portion of the article.

2. The method of claim 1 , wherein the depositing the liquid includes depositing the liquid on a previously fused portion of a powder layer of the feedstock material included in the article.

3. The method of claim 2 , further comprising, after the heating at the first temperature and prior to the heating at the second temperature, forming a powder layer of the feedstock material on at least the first portion of the article.

4. The method of claim 1 , wherein the depositing the liquid includes depositing the liquid on a powder layer of the feedstock material.

5. The method of claim 4 , wherein the deposited liquid is distributed in pores of the powder layer in the first portion of the article.

6. The method of claim 1 , wherein the heating at the first temperature includes at least one of:
heating a build chamber in which the article is disposed;
scanning the article with an energy beam;
shining at least one light onto the article; or
projecting a patterned thermal image on the article.

7. The method of claim 1 , wherein the heating at the second temperature includes scanning the article with an energy beam.

8. The method of claim 7 , wherein the energy beam is one of:
a laser; or
an electron-beam.

9. The method of claim 1 , wherein the liquid is a first liquid and the dopant is a first dopant, the method further comprising, prior to the heating at the first temperature:
depositing a second liquid on a second portion of the article, the second liquid containing a second dopant, the second dopant being different than the first dopant.

10. The method of claim 9 , wherein the second portion of the article is one of:
a portion of the article that is non-overlapping with the first portion of the article;
a portion of the article that is partially overlapping with the first portion of the article; or
a same portion of the article as the first portion of the article.

11. The method of claim 1 , wherein the liquid is a first liquid, and the method further comprises, after heating at the first temperature, and prior to heating at the second temperature:
depositing a second liquid including the dopant on the first portion of the article; and
again heating the article at the first temperature to evaporate or decompose the second liquid, so as to increase a concentration of the dopant on the first portion of the article.

12. The method of claim 1 , wherein the feedstock material is one of:
a metal;
a ceramic; or
a polymer.

13. The method of claim 1 , further comprising, during the heating at the first temperature, removing evaporated portions of the liquid from a build chamber in which the article is disposed.

14. A method for additive manufacturing, the method comprising:
depositing a liquid on a first portion of an article, the liquid including a dopant, the article including a feedstock material;
heating the first portion of the article with one or more thermal energy sources to, at least one of, evaporate or decompose the liquid, wherein the heating the first portion of the article creates a range of temperatures between a first temperature and a second temperature, the heating the first portion of the article resulting in a graded concentration of the dopant in the first portion of the article; and
after heating the first portion of the article with the one more thermal energy sources:
heating, at a third temperature different than the first temperature and the second temperature, the article, the heating at the third temperature resulting in a portion of the feedstock material melting and the dopant mixing with the feedstock material in a second portion of the article, the second portion of the article including the first portion of the article.

15. The method of claim 14 , wherein the second temperature is greater than the first temperature, a concentration of the dopant in the first portion of the article where the second temperature is applied being higher than a concentration of the dopant in the first portion of the article where the first temperature is applied.

16. The method of claim 15 , wherein the liquid is a first liquid and the dopant is a first dopant, the method further comprising, prior to the heating the first portion of the article with the one or more thermal energy sources:
depositing a second liquid on a second portion of the article, the second liquid containing a second dopant, the second dopant being different than the first dopant, the method further comprising:
heating the second portion of the article with the one or more thermal energy sources.

17. The method of claim 16 , wherein the second portion of the article is one of:
a portion of the article that is non-overlapping with the first portion of the article;
a portion of the article that is partially overlapping with the first portion of the article; or
a same portion of the article as the first portion of the article.

18. An additive manufacturing system comprising:
a build chamber configured to receive feedstock material used to produce an article;
a feedstock material source configured to provide the feedstock material to the build chamber;
a dopant printing system configured to selectively deposit a dopant containing liquid on the article during manufacturing;
a first heat source configured to heat the article to a first temperature to, at least one of, evaporate or decompose the dopant containing liquid, such that the dopant remains on the article in a pattern corresponding with the selective deposition; and
a second heat source, configured to, after heating the article to the first temperature, heat the article to a second temperature different than the first temperature to fuse the feedstock material, such that the patterned dopant is locally dispersed in the article.

19. The additive manufacturing system of claim 18 , further comprising:
a shroud configured to remove evaporated portions of the liquid from the build chamber.

20. The additive manufacturing system of claim 18 , wherein the dopant printing system includes at least one of:
an inkjet printhead;
an aerosoljet;
a syringe pump; or
a spray nozzle.

21. The additive manufacturing system of claim 18 , wherein fusing the feedstock material includes at least one of melting the feedstock material or sintering the feedstock material.

Assignees

• Brigham Young Univ Byu
• Univ Brigham Young

Inventors

• Crane Nathan Brad
• Nelson Tracy Wendell

Classifications

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B22F10/28 Primary

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F12/00

  Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices · CPC title

• B29C64/188

  involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00) · CPC title

• B29C64/153

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title