US 12,358,212 B2
System and method for ultrasound-induced additive manufacturing of polymers and composites
Ishan Joshipura, Oakland, CA (US); Martin De Beer, Berkeley, CA (US); Jordan Seiji Lum, Livermore, CA (US); Maxim Shusteff, Piedmont, CA (US); and David Matthew Stobbe, Livermore, CA (US)
Assigned to Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed by Lawrence Livermore National Security, LLC, Livermore, CA (US)
Filed on Feb. 9, 2022, as Appl. No. 17/668,205.
Prior Publication US 2023/0249397 A1, Aug. 10, 2023
Int. Cl. B29C 64/129 (2017.01); B29C 64/268 (2017.01); B29C 64/277 (2017.01); B29C 64/393 (2017.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B33Y 50/02 (2015.01); B33Y 70/10 (2020.01)
CPC B29C 64/129 (2017.08) [B29C 64/268 (2017.08); B29C 64/277 (2017.08); B29C 64/393 (2017.08); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 50/02 (2014.12); B33Y 70/10 (2020.01)] 18 Claims
OG exemplary drawing
 
1. An additive manufacturing system for at least one of forming a part or modifying a surface using a volume of polymerizable resin, the system comprising:
a memory;
a subsystem including an electronic controller in communication with the memory for generating power output signals;
a plurality of acoustic transducers placed in a vicinity of the volume of polymerizable resin, in a predetermined orientation relative to the volume of polymerizable resin, and being responsive to the power output signals;
the plurality of acoustic transducers each being modulated in a desired pattern to generate and project ultrasound energy in response to receiving the power output signals to a plurality of selected, different spatial locations within the volume of resin, wherein the ultrasound energy is selectively generated to cause cavitation bubbles to be produced at the selected, plurality of selected, different locations within the volume of resin, which cause polymerization within at least one portion of the volume of resin to at least one of form the part or modify the surface; and
at least one software module stored in the memory including at least one of:
a software algorithm; or
a look-up table; or
a pressure map,
which includes information for generating the power output signals to control at least one of frequency, amplitude or pulse duration of the ultrasound energy being emitted by the plurality of acoustic transducers, as needed, to selectively cause cavitation bubbles to be generated from the ultrasound energy at one or more locations within the volume of polymerizable resin to at least one of form the part or modify the surface; and
wherein a select one of the plurality of acoustic transducers is operated at a higher frequency and a lower power than a remainder of the plurality of acoustic transducers to operate as a monitoring transducer by producing an audible signal with a decreasing volume as polymerization progresses, and becomes imperceptible to a human ear when polymerization is complete.