Additive Manufacturing Vertical Stacking for Build Envelope Utilization

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Solution Overview

Problem

Additive manufacturing machines with faster build times have a limited build envelope, leading to idle time when producing multiple engineered-components, as they can only print one component at a time within this envelope.

Innovation Solution

A method that allows for the simultaneous formation of support structures and additional engineered-components on a single build-platform, enabling multiple components to be built stacked and separated by support structures, which can be removed post-production, optimizing the use of the build envelope.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If faster 3D printing machines are used to reduce build time, then productivity increases, but the build envelope remains limited causing idle time when producing multiple components

Engineering Contradiction:

Improvebuild speedVSAvoididle time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent applies vertical stacking of multiple engineered components on the build platform, utilizing the Z-dimension to overcome the limited horizontal build envelope. Multiple components are arranged in layers separated by support structures, allowing parallel production within the same build volume and eliminating idle time between productions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The build platform is segmented into multiple independent component regions, each capable of producing a separate engineered component. Support structures are also segmented to individually support each component layer, enabling simultaneous formation of multiple components without interference.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If multiple engineered-components are produced sequentially on a single build-platform, then manufacturing precision is maintained, but productivity decreases due to idle time between builds

Engineering Contradiction:

Improvecomponent qualityVSAvoidoutput per unit time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent enables continuous productive action by arranging multiple components to be formed simultaneously or in overlapping sequences on the same build platform. While one component is being printed, other components in different vertical layers are also being formed or are ready for the next layer deposition, eliminating idle time and maintaining continuous manufacturing flow.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If the build envelope is increased to accommodate multiple components, then productivity increases, but device complexity and cost increase

Engineering Contradiction:

Improvecomponents per buildVSAvoidbuild platform size

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple engineered components are nested vertically within the same build envelope by stacking them in layers. Each component occupies a different vertical level, supported by dedicated support structures. This nesting approach maximizes the utilization of the existing build volume without requiring horizontal expansion of the build platform.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 method increases the utilization of additive manufacturing equipment by allowing multiple components to be built within a limited space, reducing idle time and enhancing productivity, especially when building components across multiple days.

Implementation Method 1

depositing a first plurality of layers of a material onto the build-platform and solidifying the first plurality of layers

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS10576725B2Method of producing a plurality of engineered-components using an additive manufacturing process

Publication Date: 2020.03.03 APTIV TECHNOLOGIES AG

AI summary

A method of producing engineered-components using an additive manufacturing process includes the steps of, providing a build-platform, forming a first engineered-component, forming support-structures, forming a second engineered-component, and removing the support-structures. The step of providing a build-platform includes providing a build-platform on which to form an engineered-component. The step of forming a first engineered-component includes depositing a first plurality of layers of a material onto the build-platform and solidifying the first plurality of layers. The step of forming support-structures includes forming a plurality of support-structures by depositing a second plurality of layers of the material onto the build-platform and solidifying the second plurality of layers. The step of forming a second engineered-component includes depositing a third plurality of layers of the material onto the plurality of support-structures and solidifying the third plurality of layers. The step of removing the support-structures includes removing the support-structures from the second engineered-component.