Additive Manufacturing Supports for Low-Angle Aerodynamic Surfaces
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Solution Overview
Problem
Additive manufacturing methods face challenges in holding sensitive surfaces, particularly those affecting aerodynamics, leading to deformation and non-homogeneous surfaces due to the lack of effective support structures during the manufacturing process, which can alter the aerodynamic properties of complex parts like airfoils.
Innovation Solution
A method involving the addition of digital holding elements positioned on either side of sensitive surfaces in the digital model, allowing these elements to be manufactured alongside the part, which are designed to minimize contact and residue, thus preventing deformation and ensuring a homogeneous surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing is used without holding elements, then the manufacturing process is simple, but the sensitive surfaces deform and become non-homogeneous
Solution Approach 1:
The holding elements are designed and positioned in advance in the digital model before manufacturing. This preliminary action allows the holding elements to be manufactured simultaneously with the part, providing pre-established support structures that prevent surface deformation during the additive manufacturing process, thereby achieving homogeneous sensitive surfaces without requiring post-manufacturing interventions
Solution Approach 2:
The holding elements act as intermediary structures between the sensitive surfaces and the manufacturing environment. These elements provide temporary support during manufacturing, mediating the mechanical stresses and preventing direct deformation of the sensitive surfaces. After manufacturing, the holding elements are removed, leaving no residue on the surfaces
2Manufacturing precision
If holding elements are added to prevent deformation, then surface quality improves, but manufacturing time increases
Solution Approach 1:
The holding elements are merged with the main part in the digital model as a single integrated structure. This allows both the holding elements and the final part to be manufactured simultaneously in one additive manufacturing process, eliminating the need for separate manufacturing steps. The holding elements serve their support function during manufacturing and are then removed, having achieved their purpose without extending the overall manufacturing cycle
Solution Approach 2:
The holding elements are designed as temporary, disposable structures that are discarded after serving their support function. They are intentionally made easy to remove without leaving residue on the sensitive surfaces. This approach allows the holding elements to be manufactured and then quickly removed after the additive manufacturing process is complete, minimizing their impact on the total manufacturing time while ensuring surface quality
3Manufacturing precision
If holding elements are positioned to prevent deformation, then surface integrity is maintained, but contact residue occurs on sensitive surfaces
Solution Approach 1:
The holding elements are designed with localized contact features that minimize the contact area with sensitive surfaces. By concentrating support forces at specific discrete points or small regions rather than across large surface areas, the holding elements provide adequate structural support while reducing the contact footprint. This local quality approach ensures surface integrity is maintained at critical areas while minimizing residue generation at contact zones
Solution Approach 2:
The holding elements are designed as temporary, disposable structures made from materials that are easy to remove. They are intentionally designed to be sacrificial components that serve their support function during manufacturing and then can be easily removed without leaving significant residue. This approach prioritizes surface integrity during manufacturing while accepting that the holding elements themselves are temporary and will be discarded, minimizing the harmful residue effect
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 effectively prevents deformation and residue on sensitive surfaces, maintaining the aerodynamic integrity of parts like airfoils by accurately positioning holding elements based on deformation modes and allowing for easy removal without manual polishing.
Implementation Method 1
A laser beam 310 generator 300 and a control system 320 able to direct this beam 310 onto any region of the building tray 210 so as to scan any region of a layer of powder previously deposited are also used. Then, a region of this first layer 100a of powder is brought, by scanning with a laser beam 310, to a temperature greater than the melting temperature of this powder.
Implementation Method 2
By 'Selective Laser Melting' (SLM), also known under the process name 'Laser Beam Melting' (LBM), it is meant a process whose main characteristics are recalled below
Data Source
AI summary
A method for manufacturing a part by additive manufacturing, the part to be manufactured including at least one portion to be held forming an angle of less than 45° with respect to a building direction of the part to be manufactured, the portion to be held having a first lateral surface and a second lateral surface opposite each other, the method comprising the steps of: providing a digital model of the part to be manufactured, adding to the digital model at least one holding element positioned on one side of the portion to be held, so as to be in contact with said first lateral surface or said second lateral surface.