Additive nanomanufacturing system and method

Inventors: Masoud Mahjouri-Samani (Auburn, AL); Nima Shamsaei (Auburn, AL)

Assignee: AUBURN UNIVERSITY

C23C14/228 B22F10/25 B22F10/34 B22F12/53 B22F12/70 B23K26/1437 B23K26/144 B23K26/1464 B23K26/1482 B23K26/36 B28B1/001 B33Y10/00 B33Y30/00 B22F12/44 B22F12/90 B23K2103/50

View Patent ↗

Loading inventors, assignments & file history…

Monitor This Case

Get email alerts when status or documents change.

Order Certified Copies

Most orders are placed with the USPTO same day — all within 24 business hours.

Order via The Patent Place →

Pre-filled with this patent's details

Quick Facts

Patent No.: US 12668868
App. No.: 18/443,968
Granted: Jun 30, 2026
Kind: B2

External Links

USPTO Patent Center↗ Full Patent PDF↗

Abstract

A device including a chamber and a nozzle detachably connected to the chamber, the nozzle defining an aperture, a target carousel disposed within the chamber, a first laser configured to generate a first beam directed toward the target carousel to perform in-situ ablation to form a laser plume, a gas flow system configured to supply gas into the chamber, such that the gas interacts with the laser plume and causes condensation and formation of nanoparticles, and a second laser configured to generate a second beam directed through the interior of the chamber, through the aperture of the nozzle, and toward a substrate disposed outside the device, the second laser beam configured to sinter and crystalize on the substrate the nanoparticles exiting the nozzle.

Claims (35)

1 . A device comprising:

a chamber defined by a housing including at least one aperture;

one or more targets disposed within the chamber;

at least one first laser configured to generate a first beam directed through the housing and into the chamber toward the one or more targets to perform in-situ ablation to form a plume;

a gas flow system configured to supply at least one gas into the chamber and flow through the chamber such that the at least one gas interacts with the plume and causes the formation of nanoparticles that flow out of the chamber through at least one aperture; and

at least one second laser configured to generate a second beam toward a substrate disposed in an environment outside the housing maintained at atmospheric pressure, the second laser beam being configured to sinter the nanoparticles passing through the aperture on the substrate.

2 . The device of claim 1 , wherein the housing further includes a top plate and a nozzle arranged opposite the top plate, the nozzle including the at least one aperture.

3 . The device of claim 2 , wherein the first beam is directed through the housing opposite of the one or more targets.

4 . The device of claim 3 , wherein the at least one first laser is an ablation laser, and wherein the at least one second laser is a sintering laser.

5 . The device of claim 4 , wherein the at least one second laser is arranged above the top plate of the housing, and wherein the second beam is directed through the top plate and into the chamber, through the at least one aperture of the nozzle, and toward the substrate disposed in the environment outside the housing.

6 . The device of claim 1 , wherein a target carousel comprises a plate including a plurality of targets including the one or more targets about a first side of the plate and a shaft about a second side of the plate opposite the first side, and wherein the first beam performs the in-situ ablation to form the laser plume by focusing on at least one of the targets.

7 . The device of claim 1 , wherein the housing includes an outer wall, the top end plate arranged on a top end of the outer wall, wherein the nozzle is detachably coupled to a bottom end of the outer circumferential wall opposite the top end, and wherein the first beam extends through the outer wall.

8 . The device of claim 7 , wherein the one or more targets are arranged opposite a location at which the first beam extends through the outer wall such that the first beam extends transversely across the housing to the one or more targets, and wherein the second beam extends through the top plate and opposite the nozzle.

9 . The device of claim 8 , wherein the top end plate further includes one or more gas inlets through which the at least one gas is supplied into the chamber, and wherein the at least one gas is configured to flow from the gas inlets, through the chamber, and to the at least one aperture of the nozzle.

10 . A device comprising:

a chamber defined by a housing including at least one aperture;

one or more targets disposed within the chamber;

at least one first laser configured to generate a first beam directed through the housing and into the chamber toward the one or more targets to perform in-situ ablation to form a plume;

at least one second laser configured to generate a second beam toward a substrate disposed in an environment outside the housing maintained at atmospheric pressure, the at least one second laser beam configured to sinter the nanoparticles passing through the aperture on the substrate.

11 . The device of claim 10 , wherein the housing further includes a top plate and a nozzle arranged opposite the top plate, the nozzle including the at least one aperture.

12 . The device of claim 11 , wherein the first beam is directed through the housing opposite of the one or more targets.

13 . The device of claim 12 , wherein the at least one first laser is an ablation laser, and wherein the at least one second laser is a sintering laser.

14 . The device of claim 13 , wherein the at least one second laser is arranged above the top plate of the housing, and wherein the second beam is directed through the top plate and into the chamber, through the at least one aperture of the nozzle, and toward the substrate disposed in the environment outside the housing.

15 . The device of claim 10 , wherein a target carousel comprises a plate including a plurality of targets including the one or more targets about a first side of the plate and a shaft about a second side of the plate opposite the first side, and wherein the first beam performs the in-situ ablation to form the laser plume by focusing on at least one of the targets.

16 . A method comprising:

directing at least one first laser beam toward a target disposed within a chamber to perform in-situ ablation to form a laser plume;

supplying at least one gas into the chamber such that the at least one gas interacts with the laser plume, causing the formation of nanoparticles, and directs a flow of the nanoparticles toward and through an opening of the chamber, wherein the at least one gas increases pressure in the chamber to a first pressure; and

directing at least one second laser beam toward a substrate disposed adjacent to the opening of the chamber, the at least one second laser beam being configured to sinter on the substrate the nanoparticles exiting the opening in the chamber,

wherein the substrate is arranged in an environment outside of the chamber that is maintained at atmospheric pressure, and

wherein the first pressure is greater than atmospheric pressure.

17 . The method of claim 16 , wherein a nozzle including an aperture is detachably coupled to the chamber such that the opening of the chamber opens into the nozzle, wherein the at least one gas directs the flow of the nanoparticles toward and through the aperture of the nozzle, and wherein the nanoparticles are jetted through the aperture of the nozzle.

18 . The method of claim 17 , wherein a pipe extends away from the opening of the chamber, and wherein the nozzle is removably coupled to a terminal end of the pipe opposite the chamber.

19 . The device of claim 18 , wherein the chamber includes a housing having a top plate, and wherein the nozzle is arranged opposite the top plate.

20 . The device of claim 16 , wherein the chamber is arranged in the environment within which the substrate is arranged.