3D Surface Additive Manufacturing for Non-Planar Component Builds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing methods are limited to building structures on planar surfaces and lack the flexibility to create components on non-planar or three-dimensional substrates.
Innovation Solution
A method involving adhering powder to a substrate surface and using a directed energy source to fuse the powder in a pattern, allowing for layer-by-layer construction of structures on both 2-D and 3-D surfaces without the need for a conventional powder bed, enabling the creation of complex geometries like cooling channels on gas turbine components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing uses a planar powder bed process, then complete components can be manufactured, but the process cannot build structures on non-planar or 3-D surfaces
Solution Approach 1:
The patent transitions from a 2-D planar powder bed process to a 3-D surface-adaptive process by adhering powder directly to 3-D substrates. The directed energy source moves along the 3-D surface topology, building structures that conform to complex geometries rather than requiring flat layers. This dimensional extension enables additive manufacturing on curved, inclined, and non-planar surfaces.
Solution Approach 2:
The patent extracts the essential additive manufacturing function (layer-by-layer material deposition and fusion) from the conventional powder bed system. By removing the requirement for a planar powder bed and excess powder removal steps, the process is simplified to direct powder adhesion and selective fusion on the substrate surface, eliminating unnecessary process complexity.
2Manufacturing precision
If powder is adhered and fused layer-by-layer on 3-D surfaces, then structures can be built on non-planar substrates, but the process requires multiple deposition and fusing cycles
Solution Approach 1:
The patent implements continuous layer-by-layer deposition and fusion cycles without interruption. The directed energy source continuously traces the powder layer patterns, and powder is continuously adhered and fused in sequence. This continuous process minimizes idle time between operations while maintaining precise structural formation through controlled sequential layering.
Solution Approach 2:
The patent applies preliminary powder adhesion to the 3-D substrate surface before fusion. By pre-positioning the powder material in the desired pattern on the complex surface geometry, the subsequent fusion process can proceed efficiently without repositioning or realignment, reducing overall processing time while ensuring manufacturing precision.
3Productivity
If conventional additive manufacturing removes excess powder after each layer, then planar layers are maintained, but this step is unnecessary and time-consuming for 3-D surface manufacturing
Solution Approach 1:
The patent extracts and eliminates the excess powder removal step from the conventional additive manufacturing process. Since powder is adhered directly to the 3-D substrate surface in precise patterns, there is no excess powder to remove. This extraction of the unnecessary step significantly improves manufacturing efficiency by eliminating time-consuming cleaning operations.
Solution Approach 2:
The 3-D substrate surface serves its own function as both the support structure and the template for powder deposition. The complex geometry of the substrate naturally defines the build area, eliminating the need for external powder containment structures or post-deposition cleaning. The substrate itself performs the containment function that would otherwise require additional process steps.
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 simplifies the additive manufacturing process, reduces the number of steps required, and allows for cost-effective construction of components on non-planar surfaces, particularly suitable for forming cooling structures on gas turbine engine components with reduced material and processing time.
Implementation Method 1
directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a layer of the structure
Implementation Method 2
laser melted by pattern
Data Source
AI summary
A method of forming structure on a component includes: providing a component having a first surface; adhering powder to the first surface; and directing a beam from a directed energy source to fuse the powder in a pattern corresponding to a layer of the structure.