Additive Build Alignment for Prefabricated Parts and Powder Beds

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Solution Overview

Problem

In additive manufacturing, particularly in turbomachine components, accurate orientation between a construction plate and a prefabricated part is crucial to prevent geometrical deviations and collisions during selective laser melting or electron beam melting processes, as conventional methods require tight accuracy tolerances and can lead to inefficiencies and damage.

Innovation Solution

A hybrid method involving the use of a prefabricated part with a defined separating plane, optical measurement of the powder bed surface, and a fixing device to ensure accurate orientation and prevent collisions, allowing for automation and standardization of the additive construction process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If selective laser melting or electron beam melting is used to construct a structure on a prefabricated part, then complex or filigree-designed components can be produced with a short chain of process steps, but accurate orientation between the construction plate and the prefabricated part becomes necessary to prevent geometrical deviations and collisions

Engineering Contradiction:

Improveshort chain of process stepsVSAvoidaccurate orientation

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by defining a separating plane on the prefabricated part before the additive construction process begins. This separating plane serves as a pre-established reference feature that enables accurate orientation during subsequent powder coating and construction steps, thereby preventing geometrical deviations without compromising the efficiency of the additive manufacturing process.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the processing plane is not accurately parallel to the coating plane, then the additive construction process can proceed quickly, but geometrical deviations occur for the structure to be constructed

Engineering Contradiction:

Improvespeed of additive constructionVSAvoidgeometrical accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent implements feedback by using the separating plane as a reference feature that enables monitoring and adjustment of the orientation between the processing plane and the coating plane. During the additive construction process, the separating plane provides a constant reference that allows the system to detect and correct orientation deviations, ensuring geometrical accuracy while maintaining construction speed.

Inventive Principle:

Principle #23Feedback

3Device complexity

If deficient orientation occurs during postprocessing or additive construction steps, then the process can be simplified, but the construction plate cannot be used for referencing and collisions may occur between the coater and the part

Engineering Contradiction:

Improvesimplicity of processVSAvoidcollision prevention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent applies preliminary action by defining the separating plane on the prefabricated part before the additive construction process begins. This separating plane serves as a pre-established reference feature that enables accurate orientation during subsequent powder coating and construction steps, thereby preventing geometrical deviations without compromising the efficiency of the additive manufacturing process.

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 method enhances the reliability, efficiency, and quality of additive production by ensuring precise orientation and preventing collisions, thereby improving the accuracy and consistency of the components produced.

Implementation Method 1

selective laser melting (SLM) or laser sintering (SLS)

Methodology Applied

Scientific EffectSelective Laser Melting: Laser

Implementation Method 2

selective laser melting

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

electron beam melting (EBM)

Methodology Applied

Scientific EffectElectron Beam Melting: Electron Beam

Implementation Method 4

apply new powder on the processing plane (powder bed)

Methodology Applied

Scientific EffectPowder Bed Deposition: Deposition (physical)

Data Source

PatentUS11583956B2Method for the additive construction of a structure and computer program product

Publication Date: 2023.02.21 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

A method for the additive construction of a structure for a component includes the following steps: providing a prefabricated component for the component on a building board, wherein the component has a separating plane, providing a powder bed from a base material for the structure, moving the building board closer to a coating device, aligning a processing surface and the separating plane of the component for preventing adhesion between the component and the coating device, and optically measuring a surface of the powder bed.