Integrated Additive Manufacturing Cell With In-Process Inspection
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Solution Overview
Problem
Conventional manufacturing processes for turbine and rocket engine components are inefficient due to high material costs, time-consuming machining, and lack of non-destructive testing, limiting the use of complex shapes and requiring extensive secondary machining operations.
Innovation Solution
An integrated additive manufacturing cell (IAMC) that combines conventional manufacturing technologies with additive processes, enabling near-net shape production, concurrent secondary machining, and real-time inspection, allowing for local alloy tailoring and reduced material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used for turbine and rocket engine components, then material strength and high temperature resistance are achieved, but production time and cost increase significantly due to extensive machining operations
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive machining to additive manufacturing, building components layer-by-layer to achieve near-net-shape geometry. This eliminates extensive material removal operations while maintaining precise geometric control through computer-aided manufacturing processes
Solution Approach 2:
The system performs preliminary actions by pre-positioning transfer and locating features directly during the additive manufacturing process. This eliminates the need for subsequent setup operations and secondary machining operations, as components are prepared for their final operations while being manufactured
2Adaptability or versatility
If complex shapes are manufactured using conventional processes, then design flexibility is achieved, but material cost and manufacturing time increase due to hard tooling requirements
Solution Approach 1:
The patent changes the manufacturing approach from form-follows-function conventional machining to additive manufacturing where complex geometries are built directly from digital models. This eliminates the need for expensive hard tooling while maintaining design flexibility, as any geometric complexity can be achieved without additional tooling costs
Solution Approach 2:
The system applies local quality by enabling variable composition materials with different properties at different locations within the same component. This allows optimization of material properties for specific functional requirements while reducing overall material cost through targeted material placement
3Productivity
If automated manufacturing processes are implemented, then production efficiency is improved, but quality control and non-destructive testing capabilities are reduced
Solution Approach 1:
The patent implements feedback by integrating real-time non-destructive testing and inspection systems within the automated manufacturing cell. Sensors and testing equipment continuously monitor the manufacturing process and component quality, providing immediate feedback for process adjustment and defect detection
Solution Approach 2:
The system merges automated manufacturing operations with quality control and non-destructive testing functions into a single integrated cell. This combination ensures that productivity gains from automation do not compromise quality assurance, as both functions operate simultaneously in the same controlled environment
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
IAMC significantly reduces production time and costs by enabling rapid fabrication of complex geometries with minimal secondary operations, incorporating features like fixturing tabs and real-time testing, optimizing material properties and simplifying part handling.
Implementation Method 1
an additive manufacturing process that improves product quality and includes processes that require minimal material removal due to the near net shape of the workpiece
Implementation Method 2
No non-destructive testing (NDT) is included in the automated process
Data Source
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AI summary
An integrated additive manufacturing cell (IAMC) (101) that combines conventional manufacturing technologies with additive manufacturing processes is disclosed. Individual IAMCs (101) may be configured and optimized for specific part families of complex components, or other industrial applications. The IAMCs incorporate features that reduce hardware cost and time and allow for local alloy tailoring for material properties optimization in complex components. In one embodiment the IMAC (101) comprises an enclosed central manufacturing cell (103) having a plurality of access ports (105). A mechanical and electrical port interface is associated with each access port (105) to couple power, communications and mechanical utilities with an external module (107...115).