3D-Printed Engine Structures Without Internal Support Build-Up
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Solution Overview
Problem
Traditional internal combustion engines are heavy, require multiple parts, and have limitations in operating temperature and geometric consistency due to casting and machining processes, leading to inefficiencies and performance constraints.
Innovation Solution
The use of additively manufactured structures with specific orientations and materials, such as metal alloys, that eliminate the need for support structures in internal passages and incorporate features like filleted transitions and internal fluid channels, allowing for higher strength and temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional casting and machining processes are used to manufacture internal combustion engines, then the manufacturing process is well-established and parts can be produced, but the engines end up being heavy, requiring multiple assembled parts, and suffering from tolerance build-up and limited operating temperatures
Solution Approach 1:
The patent combines multiple engine components into a single monolithic structure manufactured via additive manufacturing. The engine block, cylinder heads, and internal passages are created as one integrated part, eliminating the need for assembly of multiple cast components and achieving weight reduction while maintaining structural strength.
Solution Approach 2:
The patent changes the manufacturing method from traditional casting and machining to additive manufacturing (3D printing). This parameter change enables the creation of complex internal geometries and optimized material distribution, resulting in lighter weight components with equivalent or superior strength characteristics.
2Manufacturing precision
If traditional casting processes are used, then manufacturing is straightforward, but geometric consistency and engine timing precision are limited due to tolerance build-up
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. Complex internal passages, cooling channels, and external geometries are all created in one build process, eliminating tolerance accumulation from sequential casting, machining, and assembly operations.
Solution Approach 2:
The patent replaces traditional mechanical machining processes with additive manufacturing. Instead of removing material through machining to achieve precise geometries, the system builds components layer-by-layer with inherent geometric precision, eliminating tolerance build-up associated with multiple machining operations.
3Temperature
If higher operating temperatures are desired to improve engine performance, then material strength requirements increase, but traditional materials cannot sustain these elevated temperatures
Solution Approach 1:
The patent utilizes advanced metal alloys or composite materials that maintain structural strength at elevated temperatures. These materials are deposited through additive manufacturing processes, enabling the engine components to withstand higher operating temperatures without sacrificing mechanical integrity.
Solution Approach 2:
The patent changes the material parameter from traditional cast iron or aluminum alloys to high-temperature resistant materials suitable for additive manufacturing. This material parameter change enables sustained operation at elevated temperatures while maintaining the required strength characteristics.
4Ease of manufacture
If internal passages and cooling channels are incorporated in traditional manufacturing, then support structures are required during manufacturing, but these support structures complicate the process and may interfere with internal surfaces
Solution Approach 1:
The patent replaces mechanical tool-based manufacturing with additive manufacturing for creating internal passages. The layer-by-layer deposition process can create complex internal geometries and cooling channels without requiring physical support structures that would interfere with the internal surfaces, as material is added rather than removed or formed.
Data Source
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AI summary
A method for manufacturing an additively manufactured structure for an internal combustion engine includes identifying a start point on a build plate for construction of the additively manufactured structure and identifying an orientation of the additively manufactured structure to the build plate such that surface areas of the internal body surface and each internal port surface are at least approximately 20 degrees offset from parallel to the build plate for the additively manufactured structure such that no portion of the surface areas is equivalent to an area of a circle having a radius of 5 mm or larger. The additively manufactured structure includes a body member and at least two gas ports. The body member defines an external body surface and a body bore. The body bore defines an internal body surface. Each gas port defines an external port surface and a port bore. Each port bore defines an internal port surface.