Ohio Patent of the Month – March 2025
Fabrisonic LLC has secured U.S. Patent No. 12,257,652, titled “Method for using soluble sacrificial materials in ultrasonic additive manufacturing,” introducing a breakthrough in metal 3D printing. This patented method enables the creation of intricate internal geometries within solid metal parts by utilizing water-soluble support materials that can be easily removed post-production .
Advancing Ultrasonic Additive Manufacturing
Fabrisonic’s Ultrasonic Additive Manufacturing (UAM) technology employs high-frequency sound vibrations to bond thin metal foils at low temperatures, allowing for the fusion of dissimilar metals without melting. The new patent enhances this process by introducing a technique to incorporate and subsequently dissolve sacrificial support materials, facilitating the fabrication of complex internal features such as channels and cavities .
This advancement is particularly significant for industries requiring components with embedded cooling channels or intricate internal structures, such as aerospace and automotive sectors. By enabling the removal of support materials through a simple water-based solution, the process ensures the integrity and functionality of the final metal parts without compromising structural strength.
Real-World Impact and Applications
The patented method has already demonstrated its potential in producing high-performance heat exchangers and satellite components. For instance, Fabrisonic utilized its UAM process to manufacture aluminum satellite heat exchangers with complex internal geometries, meeting stringent aerospace standards citeturn0search6.
By integrating this innovative approach, Fabrisonic continues to push the boundaries of metal additive manufacturing, offering solutions that combine design flexibility with material integrity.
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