AM Opening Mask With Support Ligaments for Clean Coating

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Solution Overview

Problem

Existing additive manufacturing methods face challenges in protecting openings on exterior surfaces of objects during coating processes, such as turbine rotor blades, as conventional blocking materials complicate manufacturing, increase time, and can cause cracking or bridging of coatings.

Innovation Solution

An additively manufactured structure with a mask over the opening, supported by ligaments, which allows for easy removal without machining, preventing coating bridging and clogging, and includes ligament remnants within the coating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If removable blocking material such as plugs is provided in the openings to prevent coating from entering, then the openings are protected during coating, but manufacturing time and complexity increase because the blocking material must be installed and removed

Engineering Contradiction:

Improveprotection of openings during coatingVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The mask is divided into multiple removable sections or panels that can be independently installed and removed from the openings. This segmentation allows for faster installation compared to traditional plugs while maintaining effective protection during the coating process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mask is pre-configured with opening definitions and protection structures before the coating process begins. This preliminary setup eliminates the need for time-consuming on-site plug installation and ensures proper protection is in place before coating application starts.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If coating is applied over blocking material, then the blocking material is covered, but removal of the coating causes cracking in the adjacent coating which may render the object unusable

Engineering Contradiction:

Improveintegrity of coatingVSAvoidease of removing blocking material

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The mask acts as an intermediary structure that provides protection during coating without requiring the coating to be applied directly over blocking material. The mask's open framework allows coating to be applied cleanly around and over it, eliminating the bridging and cracking issues associated with traditional plugs.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mask utilizes thin, flexible protective panels or films that can conform to the openings without creating rigid bridges over them. This flexibility prevents coating from spanning across the blocking material, eliminating stress concentration points that would cause cracking during removal.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If shielding features are welded on to protect the openings, then the openings are protected, but the labor hours to cover every opening can be substantial

Engineering Contradiction:

Improveprotection of openingsVSAvoidlabor hours

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The mask uses lightweight, non-welded protective panels that replicate the function of welded shields without requiring permanent attachment. These panels can be quickly installed and removed, dramatically reducing the labor hours needed compared to welding shielding features onto each opening.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The mask transitions from static welded shields to dynamic, removable protective elements. This allows the protection system to be easily installed and removed as needed, providing flexibility and reducing the permanent labor investment required for welding shields onto every opening.

Inventive Principle:

Principle #15Dynamics

4Reliability

If the mask has a larger area than the opening to overhang the exterior surface, then the mask effectively blocks coating from entering the opening, but the mask requires support structures to maintain its position

Engineering Contradiction:

Improveeffectiveness of opening protectionVSAvoidsupport structures for mask

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mask extends into the third dimension by overhanging the exterior surface, creating a protective canopy that blocks coating from entering the openings. This dimensional extension provides effective protection while the lightweight construction minimizes the complexity of support structures needed to hold it in place.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12558726B2Additively manufactured object using mask over opening for coating

Publication Date: 2026.02.24 GE INFRASTRUCTURE TECH LLC

AI summary

An additively manufactured (AM) object may include a body including an opening in an exterior surface thereof, the opening having a shape and a first area at the exterior surface of the body. A mask may be positioned over the opening. The mask has the shape of the opening and a second area that is larger than the first area so as to overhang the exterior surface of the body about the opening. A plurality of support ligaments couple to the mask and the exterior surface of the body at a location adjacent to the opening to support a portion of the mask. A coating can be applied to the object, and the mask removed. The final AM object includes a plurality of ligament elements extending from the exterior surface of the body and through the coating adjacent the opening, each ligament element at least partially surrounded by the coating.