Additive Manufacturing Build Orientation Optimization

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Solution Overview

Problem

In metal powder-based additive manufacturing, the reuse of degraded powder particles can lead to premature failure of components due to oxidation, especially in high-stress regions, posing a risk to the integrity and quality of the final product.

Innovation Solution

A method that predicts stress regions in the article and optimizes the build orientation to minimize the use of non-recycled or less recycled powder in low-stress areas, using a combination of virgin and recycled powders, where the virgin powder is used in high-stress regions and recycled powder in low-stress areas, thereby reducing material waste and maintaining product integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If recycled powder is used in high-stress regions, then production cost is reduced, but the reliability of the article deteriorates due to premature failure risk

Engineering Contradiction:

Improveproduction costVSAvoidarticle reliability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent applies local quality by differentiating powder usage based on spatial location within the article. High-value virgin powder is selectively deposited in high-stress regions identified through stress analysis, while recycled powder is used in low-stress regions. This spatial differentiation of material quality resolves the contradiction by ensuring reliability where needed while reducing costs where less critical.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the build volume into high-stress and low-stress regions through stress analysis of the CAD model. This segmentation allows differentiated powder allocation strategies: virgin powder for critical high-stress zones and recycled powder for non-critical low-stress zones, thereby resolving the contradiction between cost reduction and reliability maintenance.

Inventive Principle:

Principle #1Segmentation

2Reliability

If virgin powder is used exclusively, then article quality and integrity are maximized, but production cost increases significantly

Engineering Contradiction:

Improvearticle qualityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

Instead of uniform virgin powder usage, the patent applies local quality by restricting virgin powder to only those regions where it provides necessary value (high-stress areas). This resolves the contradiction by eliminating wasteful virgin powder usage in low-stress regions while maintaining quality where critical.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the parameter of powder selection from a constant (virgin powder throughout) to a variable parameter that changes based on spatial location and stress levels. This allows optimization of both cost and quality by matching material grade to functional requirement.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If build orientation is optimized for powder utilization, then material waste is reduced, but the manufacturing process complexity increases

Engineering Contradiction:

Improvematerial wasteVSAvoidmanufacturing process complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent performs stress analysis and build orientation optimization before the actual additive manufacturing process. This preliminary action identifies the optimal build orientation that minimizes virgin powder usage while maintaining article integrity, thereby reducing material waste without adding complexity during the manufacturing execution phase.

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 reduces production costs while ensuring the quality and integrity of the article by efficiently utilizing higher-value virgin powder in high-stress areas and recycled powder in low-stress areas, minimizing the risk of premature failure.

Implementation Method 1

The method may comprise the step of performing a stress analysis on a model of the article to predict regions of stress in the article

Methodology Applied

Scientific EffectStress analysis:

Implementation Method 2

The AM machine then deposits a layer of powder on a build platform based on the instructions it receives and the powder is subsequently selectively fused or otherwise solidified, typically with a laser or electron beam

Methodology Applied

Scientific EffectLaser heating and fusion: Laser

Implementation Method 3

Methodology Applied

Scientific EffectElectron beam heating and fusion: Electron Beam

Implementation Method 4

During a build operation unfused powder is subject to degradation. A metal powder may gradually oxidise, for example, which alters its properties

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS20220339708A1Build orientation optimisation method and system for producing an article by additive manufacturing

Publication Date: 2022.10.27 LPW TECHNOLOGY LTD

AI summary

The present application relates to a method of producing an article by additive manufacturing including the steps of predicting regions of stress in the article, identifying an optimal build orientation for the article and dispensing a first powder and/or a second powder to form the article. The first and second powders are of the same type of powder and have been recycled to different extents and the orientation of the build is optimised so that reduced quantities of the powder which has not been recycled or which has been recycled to a lesser extent is dispensed during the build.