Additive Manufacturing Hatch for Large Aspect Ratio Components
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Solution Overview
Problem
Current additive manufacturing methods, such as selective laser melting, are limited by the fixed building space size, leading to excessive powder usage and potential degradation, especially for components with large aspect ratios, where only a fraction of the powder is necessary for the actual buildup, and the large powder volume can be thermally loaded, affecting its quality.
Innovation Solution
A device with a building space wall and hatch system that allows components to be built up beyond the dimensions of the building space by guiding them partially out into an outside region, where they can be continuously extended, reducing powder usage and exposure to adverse conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the building space size is increased to manufacture components with large aspect ratios, then the component dimension is improved, but the powder consumption and cost increase substantially
Solution Approach 1:
The building space is divided into a first region (inside the building space) and a second region (outside the building space through the hatch). The component is segmented between these two regions during manufacturing, with the first portion built in the first region and the second portion extended in the second region. This segmentation allows the component to exceed the building space dimensions without requiring the entire building space to be enlarged, thus avoiding proportional increases in powder consumption.
Solution Approach 2:
The hatch provides an opening in the building space wall that enables the component to extend beyond the traditional three-dimensional bounds of the building space. By utilizing the space outside the building space through the hatch opening, the system effectively adds another dimensional pathway for component growth, allowing long components to be manufactured without increasing the building space volume proportionally.
2Length of moving object
If the building space volume is increased to accommodate long components, then the component length is improved, but the powder quality deteriorates due to thermal loading and oxidation
Solution Approach 1:
The hatch enables extraction of the component (or portions thereof) from the building space environment to an outside region during the manufacturing process. This extraction removes the component from the thermal field and controlled atmosphere of the building space, preventing unnecessary thermal loading and oxidation of the powder that would occur if the entire building space were enlarged to accommodate long components.
Solution Approach 2:
Instead of enlarging the entire building space volume (excessive action), the system uses the hatch to allow partial extension of the component outside the building space. This partial action approach achieves the needed component length while maintaining the original building space dimensions and their associated controlled environment, thus preserving powder quality.
3Length of moving object
If the building space dimensions are increased, then the component size is improved, but the manufacturing cost increases due to larger powder inventory requirements
Solution Approach 1:
The manufacturing system is segmented into two functional zones: the building space for initial component formation and the outside region (accessible through the hatch) for extended component growth. This segmentation allows the system to manufacture larger components without proportionally increasing the building space infrastructure, thus avoiding the associated costs of larger powder inventories and more complex climate control systems for the entire volume.
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
Enables the continuous and uninterrupted additive buildup of components with large aspect ratios, simplifying the manufacturing process and improving the technology by reducing powder waste and maintaining powder quality, particularly beneficial for components like those in turbomachines.
Implementation Method 1
a method for the additive buildup of components by means of selective laser melting is known from EP 2 910 362 A1, for example. To produce a component from a powder bed, for example by means of SLM, the powder bed is irradiated for example by a laser beam in accordance with the design of a corresponding CAD file.
Data Source
AI summary
A device for additive manufacturing, in particular powder-bed-based additive manufacturing, having a build-chamber wall, which defines a build chamber and is designed to separate the build chamber from an outside area. The build-chamber wall has a hatch, which is designed for transferring at least partially a component that is to be built up in layers from the build chamber through the hatch into an outside area during an additive manufacturing process, and the component can be built up along at least one transferring direction beyond a dimension of the build chamber. A corresponding method includes the provision of a first portion of the component to be manufactured in layers in the build chamber, and the building up in layers of a second portion, adjoining the first portion, wherein an already built-up sub-portion of the component is transferred in layers from the build chamber through the hatch into the outside area.