Additive Manufacturing Surface Irregularities for Part Authentication
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Solution Overview
Problem
The risk of counterfeit parts in additive manufacturing poses a threat to the integrity and compatibility of gas turbine engines, as well as the reputation and legal liability of OEMs, due to the ease of reverse engineering and copying of genuine components.
Innovation Solution
Additively manufactured components are created with surface irregularities and datum features that are difficult to detect and reproduce, using energy source manipulation to form unique identifiers that distinguish genuine parts from counterfeits, integrated into the manufacturing process without additional costs or post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing technologies are used to produce replacement parts, then manufacturing cost and accessibility are improved, but the risk of counterfeit parts and reverse engineering increases
Solution Approach 1:
The patent applies local quality by embedding unique surface irregularities at specific locations on the component surface. These localized features serve as authentication markers that are integrated into the manufacturing process itself, allowing genuine parts to be distinguished from counterfeits without affecting the overall manufacturing accessibility or cost-effectiveness of additive manufacturing
Solution Approach 2:
The patent employs asymmetry by creating non-uniform, random surface irregularities that are inherently difficult to replicate. These asymmetric surface features include variations in height, spacing, and pattern that cannot be easily copied by counterfeiters, thereby maintaining part authenticity while preserving the benefits of additive manufacturing
2Measurement precision
If surface irregularities are added for authentication, then part identification capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the authentication feature creation with the primary manufacturing process by using the same additive manufacturing technology to create both the functional component and its unique surface irregularities. This integration eliminates the need for separate authentication feature fabrication steps, thereby improving part identification accuracy without significantly increasing manufacturing process complexity
Solution Approach 2:
The patent applies preliminary action by incorporating the authentication surface irregularities during the initial manufacturing process rather than adding them as a post-processing step. The unique surface features are created simultaneously with the component itself, ensuring authentication capability is built-in from the start without complicating subsequent manufacturing or inspection processes
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 solution effectively differentiates genuine parts from counterfeits, making it difficult for unauthorized parties to replicate them, thereby ensuring part integrity and reducing the risk of engine failure and legal liability, while maintaining component quality and performance.
Implementation Method 1
manipulating the energy level of the energy source to form a surface irregularity on the surface
Data Source
AI summary
An additively manufactured component and a method for manufacturing the same are provided. The additively manufactured component includes a cross sectional layer having a surface surrounding the cross sectional layer. The cross sectional layer is formed by moving a focal point of an energy source over a bed of additive material. A surface irregularity is formed on the surface by manipulating the energy level of the energy source. The surface may include a datum feature positioned at a predetermined location relative to the surface irregularity and the surface irregularity may be greater than a surface roughness of the surface but less than one millimeter.