Method of manufacturing a three-dimensional lattice architecture

Patent metadata

Field	Value
Publication number	US-9809002-B2
Application number	US-201615151324-A
Country	US
Kind code	B2
Filing date	May 10, 2016
Priority date	May 10, 2007
Publication date	Nov 7, 2017
Grant date	Nov 7, 2017

Abstract

A three-dimensional lattice architecture with a thickness hierarchy includes a first surface and a second surface separated from each other with a distance therebetween defining a thickness of the three-dimensional lattice architecture; a plurality of angled struts extending along a plurality of directions between the first surface and the second surface; a plurality of nodes connecting the plurality of angled struts with one another forming a plurality of unit cells. At least a portion of the plurality of angled struts are internally terminated along the thickness direction of the lattice structure and providing a plurality of internal degrees of freedom towards the first or second surface of the lattice architecture.

First claim

What is claimed is:

1. A method of manufacturing a three-dimensional lattice architecture with a thickness hierarchy, the method comprising:
providing a patterned template at at least one of a top and a bottom of a container, the patterned template having at least one raised step over a flat surface;
providing a volume of photo-monomer in the container contacting the patterned template; and
exposing the photo-monomer to collimated light through a mask, the collimated light passing through a plurality of apertures of the mask at a non-perpendicular angle with respect to the mask to form a plurality of angled polymer struts in the photo-monomer at the non-perpendicular angle to form the three-dimensional lattice architecture.

2. The method of claim 1 , wherein the patterned template is provided at the bottom of the container.

3. The method of claim 1 , wherein the patterned template is provided at the top of the container.

4. The method of claim 1 , wherein the patterned template is provided at both the top and the bottom of the container.

5. The method of claim 1 , further comprising:
depositing a second material over the three-dimensional lattice architecture to form a composite lattice structure; wherein the second material is different from the polymer in the angled polymer struts.

6. The method of claim 5 , further comprising:
removing the polymer from the composite lattice structure.

7. The method of claim 1 , further comprising:
filling the three-dimensional lattice architecture with a mold forming material; and
removing the polymer to form a three-dimensional lattice structure mold.

Assignees

• Hrl Lab Llc

Inventors

• Hundley Jacob M
• Schaedler Tobias A
• Yang Sophia S
• Jacobsen Alan J

Classifications

• B32B3/12 Primary

  characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure · CPC title

• B32B9/04

  comprising such {particular} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)} · CPC title

• Y10T428/24149

  Honeycomb-like · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B32B3/30

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title