Additive Manufacturing Identification Pattern via Parameter Variation
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Solution Overview
Problem
Additive layer manufacturing (ALM) techniques face challenges in securely marking components to prevent counterfeiting, as existing methods are easily reproducible and may affect the performance or surface properties of safety-critical components like those in aerospace, and require additional processing steps or equipment.
Innovation Solution
Varying scanning and heating parameters during the ALM process creates a machine-readable identification pattern with visible surface changes that are difficult to replicate, using existing equipment in a single step, and incorporating an obfuscation pattern that requires a transparent overlay for detection, making it hard to copy without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional marking methods (coloured dyes, magnetic media, 3-D tags) are used, then the component can be marked to identify origin, but the marking is easily reproducible and may affect surface properties or require additional processing steps
Solution Approach 1:
The patent merges the marking process with the additive manufacturing process itself. The identification pattern is created during the layer-by-layer construction of the component, eliminating the need for separate marking steps. The marking is integrated into the component structure through variations in material deposition or energy input during manufacturing, making it difficult to replicate without access to the original manufacturing process parameters.
Solution Approach 2:
The patent utilizes changes in manufacturing parameters (such as energy density, scan speed, or material deposition rates) during the additive manufacturing process to create the identification pattern. By varying these parameters in specific sequences or regions, a unique marking is generated that reflects the original manufacturing conditions, making it difficult for counterfeiters to replicate without access to the exact process parameters.
2Reliability
If marking methods are applied to safety-critical components, then authentication can be provided, but the marking may affect surface properties and component performance
Solution Approach 1:
The patent applies local quality by creating the identification pattern only in specific regions of the component where it does not compromise structural integrity. The marking is placed in areas that are less critical for mechanical performance, or the marking is created using minimal energy input that does not significantly alter the surface properties. This allows authentication to be provided while maintaining the surface quality needed for safety-critical applications.
3Reliability
If additional processing steps are added for marking, then the component can be securely marked, but manufacturing costs increase
Solution Approach 1:
The patent combines the marking function with the additive manufacturing process, eliminating the need for separate marking steps. The identification pattern is created during the layer-by-layer construction of the component, so no additional processing time or equipment is required. This integration maintains security against counterfeiting while preserving manufacturing efficiency and reducing costs.
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
The method securely marks components without affecting their performance or surface properties, making it difficult for counterfeiters to reproduce, while allowing easy identification with the correct overlay, thus enhancing security and authenticity verification.
Implementation Method 1
selective laser sintering (SLS, described in US2004094728, in which a metal powder or wire is selectively heated, in order to sinter (i.e. consolidate) the powder to produce the component
Implementation Method 2
Varying scanning and heating parameters during the ALM process creates a machine-readable identification pattern with visible surface changes
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method of forming a component. The method comprises defining an identification pattern, defining one or more scanning parameters and / or one or more heating parameters, depositing a sinterable material on a substrate and scanning a heat source of the deposited sinterable material to thereby selectively sinter the material to the substrate to produce a sintered layer having the identification pattern. The sintered layer comprises first and second regions, and the method comprises sintering the first region using one or more scanning parameters and / or one or more heating parameters having a first value, and sintering the second region using one or more scanning parameters and / or one or more heating parameters having a second value to thereby produce the identification pattern comprising a contrast between the first and second regions.