Additive Manufacturing Porosity Control via Parallel Irradiation Vectors

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Additive manufacturing methods face challenges in efficiently producing intricate and porous structures with predetermined porosity, particularly in reducing thermal stresses and data processing complexity, while maintaining shaping freedom and functional properties for components like turbine parts and membranes.

Innovation Solution

A method involving the selection of parallel irradiation vectors for powder bed-based additive manufacturing, where melt pathways are non-overlapping and aligned with the structure, combined with perpendicular vectors to enhance porosity and permeability, and a computer-implemented irradiation strategy to define these patterns, allowing for complex and arbitrary shapes with improved thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional additive manufacturing methods are used to produce intricate porous structures, then shaping freedom is improved, but thermal stresses and manufacturing complexity increase

Engineering Contradiction:

Improveshaping freedomVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The irradiation process is segmented into multiple passes with different vector orientations. The first irradiation pass creates the primary structure with porosity, while subsequent passes with perpendicular vectors refine the structure and reduce thermal stresses without requiring complete process redesign

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The method performs preliminary irradiation with parallel vectors to establish the base porous structure before applying additional perpendicular irradiation vectors. This staged approach allows thermal stresses to be managed incrementally rather than all at once, reducing overall manufacturing complexity

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If conventional additive manufacturing methods are used to produce intricate porous structures, then shaping freedom is improved, but thermal stresses increase

Engineering Contradiction:

Improveshaping freedomVSAvoidthermal stresses

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The method introduces a second dimension of irradiation vectors perpendicular to the first pass. This multi-directional approach distributes thermal energy more evenly throughout the structure, preventing concentrated thermal stresses while maintaining the desired porous geometry

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The irradiation process is divided into periodic passes with alternating vector orientations. By alternating between parallel and perpendicular irradiation directions, the method allows thermal energy to dissipate between passes, reducing cumulative thermal stresses in the final structure

Inventive Principle:

Principle #19Periodic action

3Manufacturing precision

If complex irradiation strategies are used to define parallel vectors, then porosity control is improved, but data processing complexity increases

Engineering Contradiction:

Improveporosity controlVSAvoiddata processing complexity

Core Design Contradiction:

Manufacturing precisionVSLoss of information

Solution Approach 1:

The irradiation strategy is segmented into distinct vector groups (parallel vectors for primary porosity, perpendicular vectors for refinement). This segmentation allows the complex porosity control task to be divided into manageable computational steps, reducing overall data processing complexity

Inventive Principle:

Principle #1Segmentation

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 efficient production of intricate structures with tailored porosity and permeability, reducing thermal distortions and manufacturing complexity, while allowing for the creation of components with enhanced cooling capacity and heat transfer properties.

Implementation Method 1

a laser beam for selective irradiation and melting of the metal powder is pointed in a build direction z onto a build platform 1

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

selective laser melting (SLM) or selective laser sintering (SLS)

Methodology Applied

Scientific EffectSelective laser melting: Selective Laser Sintering

Implementation Method 3

The melt is solidified and a solidified structure is formed

Methodology Applied

Scientific EffectSolidification: Crystallisation

Data Source

PatentUS20240278326A1Method of powder bed-based additive manufacturing of an intricate structure with predetermined porosity and porous functional structure

Publication Date: 2024.08.22 SIEMENS ENERGY GLOBAL GMBH & CO KG

AI summary

A method of powder bed-based additive manufacturing of an intricate structure is specified, wherein the structure has a predetermined porosity, wherein a multitude of parallel irradiation vectors is chosen for selective irradiation of a powder layer for the production of the structure, wherein melt pathways generated by the parallel irradiation vectors are free of overlaps and wherein the parallel irradiation vectors also run parallel to the structure to be formed thereby. Additionally specified are a computer program product and a corresponding porous functional structure.