Optomec Design Company

James W Love

David Michael Keicher

Kevin J Dullea

James L Bullen

Pierrette H Gorman

Mark E Smith

A method and apparatus for embedding features and controlling material composition in a three-dimensional structure ( ) is disclosed. The invention enables the control of material characteristics, within a structure ( ) made from a plurality of materials, directly from computer rendering of solid models of the components. The method uses stereolithography and solid model computer file formats to control a multi-axis head ( ) in a directed material deposition process ( ). Material feedstock ( ) is deposited onto a pre-heated substrate ( ). Depositions ( ) in a layer-by-layer pattern, defined by solid models ( ), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles ( ), not available through conventional processing techniques, is enabled by embedded voids ( ) and/or composite materials ( ), which include dissimilar metals ( ). 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 ( ) within a normally solid component ( ) produces articles with diverse mechanical properties. Laser and powder delivery systems ( ) are integrated in a multi-axis deposition head ( ) having a focused particle beam ( ) to reduce material waste.

Forming structures from CAD solid models

Uniform cooling of complex surface shapes in injection mold tooling can be accomplished with cooling channels that conform to the shapes of the mold cavity or mold cone. By conventional methods this can be very difficult to accomplish. By applying methods of material deposition or material sintering, which include but are not limited to, laser metal deposition, where material is deposited on a layer by layer basis, certain cooling or heating passages could be integrated into the manufactured component that follow the contours and profiles of the mold's complex surfaces. These passages would act as internal heat sinks with a much higher surface area for heat transfer than traditional drilled and plugged straight passages. These geometries could also be incorporated into complex geometries such as, but not limited to, turbine blades where the cooling passages can follow the contour of the outer shape, provide a more uniform or controlled heat transfer from the component. Multiple loops of cooling or heating channels could be designed and manufactured into solid objects for small-scale heat exchanger technologies.

Manufacturable geometries for thermal management of complex three-dimensional shapes

A method and apparatus for embedding features and controlling material composition in a three-dimensional structure ( ) is disclosed. The invention enables the control of material characteristics, within a structure ( ) 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 ( ) in a directed material deposition process ( ). Material feedstock ( ) is deposited onto a pre-heated substrate ( ). Depositions ( ) in a layer-by-layer pattern, defined by solid models ( ), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles ( ), not available through conventional processing techniques, is enabled by embedded voids ( ) and/or composite materials ( ), which include dissimilar metals ( ). 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 ( ) within a normally solid component ( ) produces articles with diverse mechanical properties. Laser and powder delivery systems ( ) are integrated in a multi-axis deposition head ( ) having a focused particle beam ( ) to reduce material waste.

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Los Lunas, NM, United States of America

James W Love