Additive Manufacturing Alignment for Existing Component Modification
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in accurately aligning and integrating new structures with existing components, requiring high-precision alignment and being inefficient for repair or modification due to the need for exact positioning and high-quality powder usage, which limits their application in maintenance and retrofitting.
Innovation Solution
A method and device that utilize an auxiliary plate with reference markings for precise positioning and alignment of components within the additive manufacturing device, allowing for minimal alteration to existing equipment and enabling the use of external measurement data to guide the additive manufacturing process, thereby facilitating the integration of additive manufacturing in repair and maintenance technologies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-precision alignment of the component is performed in the additive manufacturing device, then the manufacturing precision of the integrated structure is improved, but the device complexity and preparation time increase significantly
Solution Approach 1:
The patent introduces an auxiliary plate as an intermediary component between the existing component and the additive manufacturing device. The auxiliary plate contains reference markings that simplify alignment by providing a standardized interface, eliminating the need for complex alignment systems within the additive manufacturing device itself. The reference markings on the auxiliary plate serve as mediators that bridge the measurement data from external measurement and the positioning requirements of the additive manufacturing process.
Solution Approach 2:
The auxiliary plate is prepared in advance with reference markings before the additive manufacturing process. The existing component is mounted on the auxiliary plate and aligned using external measurement devices before being transferred to the additive manufacturing device. This preliminary alignment and preparation work is done outside the additive manufacturing device, reducing the complexity and preparation time required within the device itself.
2Manufacturing precision
If the existing component is precisely positioned and aligned in the additive manufacturing device, then the integration accuracy is improved, but the productivity and device utilization decrease due to extended preparation time
Solution Approach 1:
The auxiliary plate acts as a mediator that enables quick and accurate positioning of the existing component. By pre-equipping the auxiliary plate with reference markings, the alignment process is simplified and can be performed rapidly using external measurement devices, reducing the time the additive manufacturing device needs to be occupied for alignment purposes.
Solution Approach 2:
The alignment and positioning process is segmented into two independent stages: (1) alignment of the existing component on the auxiliary plate using external measurement devices, and (2) transfer of the aligned assembly to the additive manufacturing device. This segmentation allows the additive manufacturing device to focus solely on the manufacturing process without being burdened by complex alignment operations, thereby improving device utilization.
3Manufacturing precision
If high-quality powder is used for additive manufacturing of existing components, then the manufacturing precision and surface quality are improved, but the cost increases significantly
Solution Approach 1:
The auxiliary plate with reference markings enables precise localization and positioning of the existing component on the powder bed. This ensures that additive manufacturing is performed only in the specific areas where new material needs to be applied, rather than requiring high-quality powder for entire components. The local quality principle allows selective use of premium powder only where structurally necessary.
Solution Approach 2:
The reference markings on the auxiliary plate create a reproducible positioning system that can be used across multiple manufacturing runs. Once the alignment is established using external measurement devices and the auxiliary plate, the same positioning can be replicated for subsequent components or repair areas, reducing the need for repeatedly using expensive high-quality powder for alignment-related material application.
Data Source
AI summary
A method for building structures on existing components includes preparing an auxiliary plate suitable for fastening on the working plate, wherein the auxiliary plate has at least one reference marking, fastening the component on the auxiliary plate, optionally processing the at least one surface to be processed for providing a surface that is substantially parallel to the working plane of the device, measuring the at least one reference marking and the component, wherein the position is recorded, introducing the auxiliary plate with the at least one reference marking and the component into the device and detachably fastening the auxiliary plate on the working plate and processing the component in the device for additive manufacturing by working data on the basis of measuring data. A device and a composite structure for additive manufacturing is used in the method.