Additive Manufacturing Elongate Portion Channel Design
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Solution Overview
Problem
Additive layer manufacturing methods face challenges in producing three-dimensional objects with elongate portions at angles greater than 50° to the gravitational direction, leading to material sinking and the need for additional support structures, which increase weight and cost.
Innovation Solution
The method involves constructing elongate portions with multiple longitudinal channels at angles greater than 45° to the gravitational direction, minimizing the distance between channels and the outer surface, allowing for reduced or eliminated internal support structures by maintaining a consistent wall thickness and optimizing channel diameters, such as up to 7 mm, to prevent material sinking and reduce material expenditure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive layer manufacturing is used to produce elongate portions at angles greater than 50° to gravitational direction, then complex geometries can be produced, but material sinking occurs and additional support structures are required
Solution Approach 1:
The patent divides the internal structure into multiple longitudinal channels separated by wall regions. This segmentation allows each channel to be supported by adjacent channels and walls, distributing the structural support load and preventing material sinking in overhanging areas while maintaining complex internal geometries
Solution Approach 2:
The patent applies different structural characteristics to different regions: channel regions are optimized for fluid conveyance while wall regions provide structural support. The wall thickness and channel diameter are locally optimized to prevent sinking in overhanging areas while maintaining manufacturing efficiency
2Manufacturing precision
If additional support structures are added to prevent material sinking, then manufacturing precision is improved, but object weight and production cost increase
Solution Approach 1:
The longitudinal channels serve dual functions: they convey fluid through the object and simultaneously provide structural support to prevent material sinking in overhanging areas. This eliminates the need for separate support structures, reducing object weight while maintaining manufacturing precision
Solution Approach 2:
The internal channel structure supports itself by using the channels and walls to provide mutual structural reinforcement. The geometry is designed so that the channels and walls naturally prevent material sinking without requiring additional external or internal support elements
3Manufacturing precision
If wall thickness and channel diameter are optimized to prevent material sinking, then manufacturing precision is improved, but production time may increase
Solution Approach 1:
The patent optimizes specific parameters including wall thickness (at least 0.5 mm) and channel diameter (up to 7 mm) to prevent material sinking. These parameter ranges are selected to balance manufacturing precision with production efficiency, allowing rapid manufacturing while preventing defects
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 the cost-effective and time-efficient production of three-dimensional objects with complex geometries by minimizing the need for internal support structures, maintaining structural integrity, and achieving cleaner inner surfaces without defects.
Implementation Method 1
each layer is irradiated, before the following layer is applied, with a laser beam or a particle beam selectively only in the areas of the layer which correspond to the three-dimensional object to be produced. The irradiation takes place in such a way that the powder material in the corresponding areas is locally melted or sintered.
Implementation Method 2
the powder material in the corresponding areas is locally melted or sintered
Implementation Method 3
each layer is irradiated, before the following layer is applied, with a laser beam or a particle beam selectively only in the areas of the layer which correspond to the three-dimensional object to be produced. The irradiation takes place in such a way that the powder material in the corresponding areas is locally melted or sintered.
Implementation Method 4
the powder material in the corresponding areas is locally melted or sintered
Data Source
AI summary
An additive layer manufacturing method is disclosed for producing a three-dimensional object and a corresponding object. Layers of powder material are applied to a carrier and each layer is irradiated with a laser beam or a particle beam only in areas of the layer corresponding to the three-dimensional object to be produced. Irradiation occurs so the powder material in the corresponding areas is locally melted or sintered. An elongate portion of the object is constructed so longitudinal channels extend at an angle of more than 45° to the direction of the force of gravity, and along its entire length the longitudinal channels are formed so that in cross section perpendicular to the direction of extension of the elongate portion the minimum distance to the outer surface of the elongate portion is not smaller than the minimum distance to the closest neighbouring longitudinal channel or the closest neighbouring longitudinal channels.