초록 ▼

A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer renderings of sol

A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer renderings of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head (480) in a directed material deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional processing techniques, is enabled by embedded voids (152) and/or composite materials (126, 127), which include dissimilar metals (210, 216). Finished articles control pressure drop and produce uniform coolant flow and pressure characteristics. High-efficiency heat transfer is engineered within a solid structure by incorporating other solid materials with diverse indexes. Embedding multi-material structures (132, 134) within a normally solid component (141) produces articles with diverse mechanical properties. Laser and powder delivery systems (420, 170) are integrated in a multi-axis deposition head (480) having a focused particle beam (502) to reduce material waste.

대표청구항 ▼

1. A method comprising the steps of:defining a solid model (141, 146) which describes a finished three-dimensional structure (130), said solid model (141, 146) having embedded features, in a computer-aided design program stored on a control computer (129); depositing a layer (15) of material feedsto

1. A method comprising the steps of:defining a solid model (141, 146) which describes a finished three-dimensional structure (130), said solid model (141, 146) having embedded features, in a computer-aided design program stored on a control computer (129); depositing a layer (15) of material feedstock (126, 127) on a substrate (19) using a directed material deposition process (123); said deposition process (123) controlled by said computer-aided design program; creating a plurality of said embedded features in said finished three-dimensional structure (130) by including regions (152) having voids, regions (132, 134) including a first material (126) and regions (136) including a plurality of materials (126, 127); and forming said finished three-dimensional structure (130) having said plurality of embedded features by repeating said depositing, in a layer-by-layer manner, according to said solid model (141, 146).