Additive Manufacturing Small Adaptive Engines
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Solution Overview
Problem
Current manufacturing processes for small engines are costly and inefficient, particularly in producing complex parts like turbine blades, and are often dependent on market size and lead times, limiting adaptability and responsiveness in industries such as defense.
Innovation Solution
The implementation of additive manufacturing (AM) processes, facilitated by a battlefield repository with cloud-based services and machine learning programs, using alloy powders produced through cold hearth mixing and gas atomization, and employing systems like laser powder bed fusion, to reduce costs and increase adaptability in producing engine parts and assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining processes are used to manufacture complex engine parts, then manufacturing precision can be achieved, but manufacturing cost and lead time increase significantly
Solution Approach 1:
The patent replaces traditional mechanical machining processes with additive manufacturing technology. The additive manufacturing system uses digital models to directly fabricate complex engine parts layer by layer, eliminating the need for time-consuming mechanical cutting and shaping operations while maintaining manufacturing precision and reducing lead times.
Solution Approach 2:
The patent employs preliminary digital modeling and simulation before physical manufacturing. The engine parts are designed and optimized in virtual environments using computer-aided design (CAD) software, allowing for precision planning and verification before actual production, thereby reducing overall manufacturing lead time while ensuring precision.
2Productivity
If market-size dependent manufacturing models are used, then economies of scale can be achieved, but adaptability to changing demands decreases
Solution Approach 1:
The patent implements a dynamic manufacturing model where additive manufacturing systems can rapidly adjust production parameters, material selection, and design configurations to meet changing market demands. The system transitions from static, volume-based production to flexible, demand-driven manufacturing that can adapt to various engine configurations and customer requirements without significant retooling costs.
Solution Approach 2:
The patent utilizes parameter changes in the additive manufacturing process to accommodate different engine designs and specifications. By adjusting manufacturing parameters such as layer thickness, material composition, and geometric constraints, the system can efficiently produce varied engine parts and complete engines tailored to specific applications, thereby achieving both efficiency and adaptability.
3Manufacturing precision
If complicated machining processes are used to produce complex engine parts, then manufacturing precision can be maintained, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive and complicated mechanical machining processes with additive manufacturing technology. This substitution eliminates the need for costly tooling, fixtures, and multiple machining operations while maintaining manufacturing precision through digital control and automated positioning systems, thereby significantly reducing manufacturing costs for complex engine parts.
Solution Approach 2:
The patent merges multiple manufacturing operations into a single additive manufacturing process. Instead of requiring separate steps for forming, machining, and assembly, the additive manufacturing system integrates these functions into one continuous process that builds complex parts directly, reducing overall manufacturing cost while preserving precision through unified process control.
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 enables low-cost, on-demand manufacturing of small adaptive engines with reduced lead times and increased adaptability, allowing for rapid innovation and response to changing demands, while maintaining high precision and functionality.
Implementation Method 1
the additive manufacturing (AM) system includes a laser powder bed fusion (LPBF) system having layer-by-layer powder bed monitoring
Implementation Method 2
laser powder bed fusion (LPBF) system having layer-by-layer powder bed monitoring
Implementation Method 3
a gas atomization system for forming the alloy powder
Implementation Method 4
a cold hearth mixing system for melting a feedstock
Data Source
AI summary
A method for manufacturing small adaptive engines uses a battlefield repository having cloud services that is configured to enable additive manufacturing (AM) of engine parts and assemblies. The method also uses a compilation of recipes/signatures for building the engine parts and the assemblies using additive manufacturing (AM) processes and machine learning programs. An additive manufacturing system and an alloy powder suitable for performing the additive manufacturing (AM) processes can be provided. In addition, the engine parts can be built using the additive manufacturing (AM) system, the alloy powder, the battlefield repository and the compilation of recipes/signatures. A system for manufacturing small adaptive engines includes the battlefield repository, the compilation of recipes/signatures, a foundry system for providing the alloy powder and an additive manufacturing (AM) system configured to perform the additive manufacturing (AM) processes.