Additive Manufacturing Fixture for Precise Part Alignment
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Solution Overview
Problem
Existing additive manufacturing methods for repairing parts, such as turbine blades, require complex and time-consuming alignment processes due to the need for determining the part's position relative to the coordinate system of the energy beam, especially when multiple parts need to be repaired simultaneously.
Innovation Solution
A method involving the creation of a fixture with known geometry, which allows for the part to be mounted in a predetermined position, enabling the determination of a scan path for the energy beam based on the fixture's position, and using kinematic mounts to ensure repeatable positioning of the build plate within the additive manufacturing apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a part is mounted within a build chamber for additive manufacturing repair, then the part can be processed by the energy beam, but complex and time-consuming alignment processes are required to determine the part's position relative to the coordinate system of the energy beam
Solution Approach 1:
A fixture with known geometry is manufactured beforehand using the additive manufacturing apparatus. This fixture serves as a reference object with predetermined coordinates in the energy beam's coordinate system, eliminating the need for complex alignment measurements during the repair process. The fixture is built on a build plate that is retained in a set position within the apparatus.
Solution Approach 2:
The fixture acts as an intermediary reference object between the energy beam coordinate system and the part to be repaired. By mounting the part to the fixture, the known geometry of the fixture provides a reference framework that simplifies position determination. The fixture's known coordinates allow direct calculation of the part's position without complex alignment procedures.
2Productivity
If multiple parts are repaired simultaneously using additive manufacturing, then productivity increases, but the complexity of determining positions and scan paths for multiple parts increases significantly
Solution Approach 1:
Multiple fixtures with known geometries are manufactured and mounted on the same build plate. Each fixture serves as an independent reference object for the parts it holds. This segmentation allows each part's position to be determined relative to its own fixture's known coordinates, simplifying the overall alignment process for multiple parts.
Solution Approach 2:
The build plate serves as a universal mounting platform that can hold multiple fixtures simultaneously. The build plate is retained in a set position within the additive manufacturing apparatus, providing a common reference frame for all fixtures and parts. This multi-functionality enables simultaneous repair of multiple parts while maintaining a unified coordinate system.
3Measurement precision
If the build plate is removed from the apparatus for measuring the part and fixture, then measurement accuracy can be improved, but the build plate must be repositioned with high precision to maintain the known position relationship
Solution Approach 1:
A kinematic mount system replaces complex mechanical positioning mechanisms. The mounting formations on the build plate and build support engage to automatically locate the build plate in a repeatable position within the additive manufacturing apparatus. This kinematic mounting system provides precise repositioning through geometric constraints rather than mechanical adjustment, eliminating the need for complex repositioning procedures.
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
Facilitates efficient and precise alignment of the energy beam with the part, allowing for simultaneous repair of multiple parts in a single build, reducing the complexity and time required for alignment processes.
Implementation Method 1
consolidating material directly on to the pre-formed part using an additive manufacturing process... material is consolidated using an energy beam... selective laser melting/sintering (SLM/SLS)
Implementation Method 2
additive manufacturing, such as selective laser melting/sintering (SLM/SLS)... consolidate material onto the part
Data Source
AI summary
A method and apparatus for manufacturing or repairing a part. The method includes building a fixture for retaining the part using an additive manufacturing apparatus, wherein material is consolidated using an energy beam, the fixture built on a build plate retained in a set position within the additive manufacturing apparatus, mounting the part to the fixture and causing the additive manufacturing apparatus to consolidate material onto the part when the build plate, with the fixture and part attached thereto, is retained substantially in the set position.