3D-Printed Pressure Vessel Nozzle Units for Faster Custom Manufacturing

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Solution Overview

Problem

Existing nozzle manufacturing methods for pressure vessels, such as forging and machining, lead to long delivery times and require significant effort, making it challenging to produce nozzles efficiently and cost-effectively.

Innovation Solution

The use of additive manufacturing (3D printing) to produce nozzle units as integral, one-piece parts, allowing for easy customization of geometric and chemical properties, reduced material usage, and minimized need for welding or reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional forging and machining methods are used to manufacture nozzles, then the nozzles can be produced with conventional manufacturing processes, but the delivery time and manufacturing effort increase significantly

Engineering Contradiction:

Improvenozzle manufacturing qualityVSAvoiddelivery time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces traditional mechanical forging and machining processes with additive manufacturing technology. This substitution enables direct digital fabrication of nozzles layer by layer, eliminating the need for extensive material removal and assembly operations, thereby significantly reducing manufacturing lead time while maintaining or improving product quality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes additive manufacturing parameters (such as layer thickness, heating power, scanning speed, and material composition) to directly control nozzle geometry and material properties. By optimizing these parameters, the process achieves high manufacturing precision and quality without requiring post-machining operations, thus reducing overall manufacturing time

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If traditional forging and machining methods are used to manufacture nozzles, then conventional manufacturing processes can be employed, but the manufacturing effort and complexity increase

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent merges multiple traditional manufacturing steps (forging, machining, heat treatment, and assembly) into a single additive manufacturing process. The nozzle is created directly in its final form with integrated features, eliminating the need for separate operations and reducing manufacturing complexity while improving productivity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process serves multiple functions simultaneously: it forms the nozzle geometry, controls material properties, creates complex internal structures, and produces the final part ready for installation. This multi-functionality simplifies the manufacturing workflow and enhances overall manufacturing efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If nozzles are manufactured using traditional methods, then standard production processes can be used, but customization of geometric and chemical properties becomes difficult

Engineering Contradiction:

Improvenozzle customization capabilityVSAvoidmanufacturing effort

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent enables local customization of nozzle properties through additive manufacturing, allowing different sections of the nozzle to have tailored material compositions, densities, and geometric features. This local quality control is achieved by varying printing parameters during fabrication, enabling optimization for specific functional requirements without increasing manufacturing effort

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent incorporates design optimizations and material property adjustments directly into the additive manufacturing process before production begins. By pre-configuring digital models with optimized geometries and material distributions, the system achieves high adaptability for custom applications while maintaining efficient manufacturing through automated process control

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly reduces manufacturing time, effort, and delivery times while enabling the production of custom-made nozzle units with optimized properties for specific pressure vessels, such as improved fatigue resistance and reduced corrosion.

Implementation Method 1

In this process, a new layer of material is successively applied to the previously created object, solidified and firmly bonded to the underlying layers, e.g. with the aid of a laser, electron beam or electric arc

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

Methodology Applied

Scientific EffectElectron beam: Electron Beam

Implementation Method 3

Methodology Applied

Scientific EffectElectric arc: Electric Arc

Data Source

PatentEP4541496A1A method for manufacturing a nozzle unit for a pressure vessel

Publication Date: 2025.04.23 LINDE AG

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AI summary

The present invention relates to a method for manufacturing a nozzle unit (200) for a pressure vessel (100), especially for a pressure vessel of a pressure swing adsorption device, comprising the step of: manufacturing the nozzle unit (200) by means of an additive manufacturing process.