3D-Printed Welding Torch Head for Compact Function Integration
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Solution Overview
Problem
Conventional welding torches are expensive to manufacture and have limited miniaturization possibilities, making it difficult to integrate complex functions like cooling, shielding gas supply, instrumentation, and remote vision, especially in confined or inaccessible areas such as those found in the nuclear industry or heavy equipment maintenance.
Innovation Solution
The welding torch is manufactured using additive manufacturing (3D printing) with a metal body that conducts electricity, allowing for the integration of functions like electric current supply, shielding gas, and filler metal wire passage, while the insulating sheath isolates the filler metal wire from the body's electrical potential, enabling compact and complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes (machining, assembling parts from different materials) are used, then the welding torch can be manufactured with traditional materials, but the manufacturing cost is high and miniaturization possibilities are limited
Solution Approach 1:
The patent merges multiple previously separate components (body, cooling channels, gas supply passages, electrode holder) into a single monoblock structure manufactured by additive manufacturing. This eliminates the need for assembling parts from different materials and integrates multiple functions (cooling, gas supply, electrical conduction) into one component, thereby reducing manufacturing cost and complexity while enabling miniaturization
Solution Approach 2:
The monoblock body serves multiple functions simultaneously: it provides structural support, conducts electricity to the electrode, contains internal cooling channels, and incorporates gas supply passages. This multi-functionality is achieved through additive manufacturing, which allows complex internal geometries to be integrated into a single component, reducing the number of separate parts and assembly steps
2Volume of moving object
If the welding torch is miniaturized to access confined areas, then accessibility to repair areas is improved, but the integration of multiple functions (cooling, gas supply, instrumentation) becomes more difficult
Solution Approach 1:
The patent nests multiple functional elements within the monoblock structure: cooling channels are embedded within the body, gas supply passages are integrated into the same structure, and the electrode holder is formed as part of the monoblock. This nesting of functions within a compact monoblock structure enables miniaturization while maintaining the ability to integrate multiple functions, as the additive manufacturing process allows complex internal geometries to be created without increasing external dimensions
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 results in a cost-effective, compact welding torch capable of performing complex welding operations in confined spaces with integrated functions like cooling, shielding gas supply, and remote vision, suitable for areas inaccessible to operators.
Implementation Method 1
the body being obtained by additive manufacturing in a metal conducting electricity, the electrode being electrically connected to the source of electric current by the metal constituting the body
Data Source
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AI summary
The present invention relates to welding torches (1) that comprise a head (3) having a body (11) bearing an electrode (13), a source of electric current (27), a metal filler wire and a wire guide (19) guiding the metal filler wire to the electrode (13), the body (11) being obtained by additive manufacturing from an electrically conductive metal and the wire guide (19) comprising an insulating sheath (29) inside which the metal filler wire moves.