Abstract

There is provided a method (300) of manufacturing a porous material. The method (300) comprises the steps (301, 302) of: a) forming a powder layer (170), the powder layer (170) comprising a first precursor powder (123), and b) applying a laser beam (134) to modify the powder layer (170) in selected regions of the powder layer to form a porous material layer. The step (302) of applying a laser beam (134) comprises controlling one or more parameters of the laser beam (134) to control the pore structure of the porous material layer. The one or more parameters of the laser beam (134) comprises the shape and/or size of a laser beam spot on the powder layer (170).

IPC Classes  ?

• B22F 1/00 - Metallic powderTreatment of metallic powder, e.g. to facilitate working or to improve properties
• B22F 1/18 - Non-metallic particles coated with metal
• B22F 3/11 - Making porous workpieces or articles
• B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• B22F 10/36 - Process control of energy beam parameters
• B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
• B33Y 10/00 - Processes of additive manufacturing
• C22C 1/08 - Alloys with open or closed pores
• G02B 27/09 - Beam shaping, e.g. changing the cross-sectioned area, not otherwise provided for
• C22C 1/04 - Making non-ferrous alloys by powder metallurgy
• B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• B22F 12/44 - Radiation means characterised by the configuration of the radiation means
• B22F 12/55 - Two or more means for feeding material
• B22F 12/60 - Planarisation devicesCompression devices
• C22C 26/00 - Alloys containing diamond
• B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups

Abstract

There is provided a method of manufacturing a multi-material device. The method 200 comprises the steps of: a) forming a powder layer 201, the powder layer 170 comprising a first precursor powder 123 and a second precursor powder 125, wherein the first precursor powder 123 and the second precursor powder 125 are arranged in a predetermined pattern, and b) melting or sintering the powder layer 170 in selected regions of the powder layer 170 to form a multi-material device layer 202. The first precursor powder 123 comprises metal particles and the second precursor powder 125 comprises semiconductor particles.

IPC Classes  ?

• B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• B22F 12/55 - Two or more means for feeding material
• B33Y 10/00 - Processes of additive manufacturing
• B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
• H10D 30/60 - Insulated-gate field-effect transistors [IGFET]
• H10N 10/01 - Manufacture or treatment
• H10N 10/851 - Thermoelectric active materials comprising inorganic compositions

Abstract

There is provided a method 200 of forming a diamond metal matrix composite 160. The method comprises the steps of: a) forming a powder layer 201, the powder layer comprising a precursor powder 110, and b) melting or binding the powder layer in selected regions of the powder layer to form a diamond metal matrix composite layer 202. The precursor powder 110 comprises coated particles 10, wherein each coated particle 10 comprises a diamond 12 coated by an outer shell layer 14, and wherein the outer shell layer 14 comprises a highly thermally conductive metal or alloy thereof. There is also provided the use of the precursor powder 110 in an additive manufacturing process to form a diamond metal matrix composite 160, and a diamond metal matrix composite 160 formed by such a method 200 for use in thermal management applications.

IPC Classes  ?

• B22F 10/36 - Process control of energy beam parameters
• B22F 1/18 - Non-metallic particles coated with metal
• C22C 26/00 - Alloys containing diamond
• B22F 10/14 - Formation of a green body by jetting of binder onto a bed of metal powder
• B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
• B33Y 10/00 - Processes of additive manufacturing
• B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials