A method and apparatus for embedding features and controlling material composition in a three-dimensional structure (130) is disclosed. The invention enables the control of material characteristics, within a structure (130) made from a plurality of materials, directly from computer renderings of
solid models of the components. The method uses
stereolithography and
solid model
computer file formats to control a multi-axis head (480) in a directed material
deposition process (123). Material feedstock (126, 127) is deposited onto a pre-heated substrate (19). Depositions (15) in a layer-by-layer pattern, defined by
solid models (141, 146), create a three-dimensional article having complex geometric details. Thermal management of finished solid articles (250-302), not available through conventional
processing techniques, is enabled by embedded voids (152) and / or composite materials (126, 127), which include dissimilar metals (210, 216). Finished articles control pressure drop and produce uniform
coolant flow and pressure characteristics. High-efficiency
heat transfer is engineered within a
solid structure by incorporating other solid materials with diverse indexes. Embedding multi-material structures (132, 134) within a normally
solid component (141) produces articles with diverse mechanical properties.
Laser and
powder delivery systems (420, 170) are integrated in a multi-axis deposition head (480) having a focused
particle beam (502) to reduce material waste.