Additive Manufacturing Model Assembly Cost Reduction
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Solution Overview
Problem
Additive manufacturing technologies face challenges in reducing manufacturing costs while maintaining the advantages of producing complex three-dimensional components, as the cost increases with the volume of the component due to the layer lamination process, making it difficult to achieve a balance between added value and cost reduction.
Innovation Solution
The approach involves assembling an additive manufacturing model formed by melting laminated metal powder with a non-additive manufacturing model using a different method, where the additive manufacturing model is thinner at the contact points to reduce costs, and the components are fixed using brazing materials or other joining techniques, allowing for a combination of additive and non-additive manufacturing methods to optimize performance and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive manufacturing is used to manufacture a component with large volume, then the component can have a fine and complicated three-dimensional shape, but the manufacturing cost increases due to the increased number of lamination times
Solution Approach 1:
The heat exchanger is divided into multiple components: a heat exchanger body manufactured by additive manufacturing and pipelines manufactured by conventional methods. This segmentation allows each component to be optimized for its specific manufacturing requirements, reducing overall cost while maintaining complex geometry where needed.
Solution Approach 2:
Additive manufacturing is applied locally only to the heat exchanger body where complex three-dimensional shapes are required, while pipelines with simpler geometries are manufactured using conventional methods. This local application of advanced manufacturing technology optimizes the balance between shape complexity and manufacturing cost.
2Productivity
If additive manufacturing is used to manufacture a component, then the manufacturing time can be reduced compared to conventional assembly methods, but the manufacturing cost may increase due to the number of lamination times
Solution Approach 1:
The heat exchanger is segmented into a heat exchanger body and separate pipelines. The body is manufactured by additive manufacturing to reduce assembly time, while pipelines are manufactured by conventional methods to reduce cost, achieving an optimal balance between productivity and manufacturing cost.
Solution Approach 2:
The heat exchanger body and pipelines are merged into a single integrated assembly through fixed connection, combining the productivity benefits of additive manufacturing with the cost benefits of conventional manufacturing methods.
3Ease of manufacture
If the thickness of the additive manufacturing model at the contact portion is made thinner, then the manufacturing cost can be reduced, but the strength and rigidity at the contact portion may be compromised
Solution Approach 1:
The additive manufacturing model is designed with locally optimized thickness: thinner at contact portions to reduce cost and weight, and thicker at other portions to maintain structural strength and rigidity. This local quality variation achieves cost reduction without compromising overall component performance.
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 enables the production of additive manufacturing model assemblies at a lower cost while maintaining the performance benefits of additive manufacturing, by separating the components into thinner additive and thicker non-additive parts, reducing manufacturing time and cost compared to solely additive manufacturing.
Implementation Method 1
an additive manufacturing model formed by additive manufacturing in which laminated metal powder is melted
Implementation Method 2
the components are fixed using brazing materials or other joining techniques
Data Source
AI summary
An additive manufacturing model assembly includes: an additive manufacturing model formed by additive manufacturing in which laminated metal powder is melted; and a metal non-additive manufacturing model formed by a method different from the additive manufacturing, the additive manufacturing model assembly is configured by assembling the additive manufacturing model and the non-additive manufacturing model, the additive manufacturing model assembly has: a contact portion at which the additive manufacturing model and the non-additive manufacturing model are in contact with each other; and a fixing portion by which the additive manufacturing model and the non-additive manufacturing model are fixed to each other, the fixing portion being located at a same position as the contact portion or a position different from the contact portion, and a thickness of the additive manufacturing model is thinner than a thickness of the non-additive manufacturing model at the contact portion.