US 11,858,039 B2
Direct ink printing of multi-material composite structures
Seyed Mohammad Sajadi, Houston, TX (US); Peter Boul, Houston, TX (US); Chandra Sekhar Tiwary, Houston, TX (US); Muhammad M. Rahman, Houston, TX (US); Pulickel M. Ajayan, Houston, TX (US); and Carl Thaemltiz, Houston, TX (US)
Assigned to Saudi Arabian Oil Company, Dhahran (SA); and William Marsh Rice University, Houston, TX (US)
Filed by Saudi Arabian Oil Company, Dhahran (SA); and William Marsh Rice University, Houston, TX (US)
Filed on Jan. 13, 2022, as Appl. No. 17/575,177.
Prior Publication US 2023/0219138 A1, Jul. 13, 2023
Int. Cl. B22F 10/18 (2021.01); B22F 12/58 (2021.01); B22F 12/55 (2021.01); B22F 12/53 (2021.01); B22F 1/103 (2022.01); B33Y 40/10 (2020.01); B33Y 70/10 (2020.01); B33Y 10/00 (2015.01)
CPC B22F 10/18 (2021.01) [B22F 1/103 (2022.01); B22F 12/53 (2021.01); B22F 12/55 (2021.01); B22F 12/58 (2021.01); B33Y 10/00 (2014.12); B33Y 40/10 (2020.01); B33Y 70/10 (2020.01); B22F 2301/10 (2013.01); B22F 2301/35 (2013.01); B22F 2302/40 (2013.01); B22F 2998/00 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A method for fabricating a multi-material composite structure, the method comprising:
forming a first colloidal ink solution comprising a first material matrix, water, and a rheology modifying agent, wherein the first material matrix comprises iron;
forming a second colloidal ink solution comprising a second material matrix, water, and a rheology modifying agent, wherein the second material matrix comprises copper;
printing, by direct ink writing, a first layer on a substrate using a first printing nozzle carrying the first colloidal ink solution;
printing, by direct ink writing, a second layer on top of the first layer using a second printing nozzle carrying the second colloidal ink solution;
forming a 3D structure by printing, by direct ink writing, a plurality of layers comprising the first layer and the second layer printed in an alternating pattern; and
sintering the 3D structure to form the multi-material composite structure, the multi-material composite structure comprising a copper-iron composite structure.