Powder Removal Aperture Layout in AM Components

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Solution Overview

Problem

The manual process of inserting powder removal holes in additively manufactured components is inefficient and often suboptimal, requiring repeated Finite Element Analysis and labor-intensive modifications to ensure structural integrity and effective powder removal.

Innovation Solution

An automated method for determining the optimal size and location of apertures and channels for powder removal, integrated with the 3D printing process, which updates the component model to include these features and ensures structural integrity through analysis and simulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual hole placement is used in CAD models for powder removal, then powder removal capability is provided, but the process becomes labor-intensive and inefficient

Engineering Contradiction:

Improvepowder removal feature insertion efficiencyVSAvoidtime for repeated FEA and manual modifications

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The system performs self-service by automatically analyzing the 3D model, identifying powder trapping regions, and generating optimal aperture placements without requiring manual intervention. The automated algorithm independently completes tasks that previously required repeated manual hole placement and FEA analysis cycles

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical process of placing holes and running FEA tests is replaced by an automated computational system. The algorithm substitutes human operators and iterative manual modification processes with automated software that performs structural analysis and aperture optimization

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If manual hole placement with guesswork is used, then powder removal features are created, but optimal configurations are not achieved and holes may be placed in difficult-to-access portions

Engineering Contradiction:

Improveaperture location optimizationVSAvoiddifficulty of accessing placed holes

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The system uses feedback from structural analysis and powder flow simulation to continuously refine aperture placements. The algorithm analyzes the results of each placement iteration and adjusts subsequent hole positions to optimize both powder removal effectiveness and structural integrity, avoiding difficult-to-access locations

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary analysis of the 3D model to identify optimal aperture locations before manufacturing. By pre-calculating the best hole placements that ensure both accessibility and structural integrity, the system avoids the need for post-manufacturing adjustments and ensures optimal configurations from the start

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the manual process is repeated multiple times for different component types, then structural integrity is maintained, but productivity decreases as the number of components increases

Engineering Contradiction:

Improvestructural integrityVSAvoidthroughput of additively manufactured components

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The automated system provides universal applicability across different component types and geometries. A single automated algorithm handles diverse component configurations, maintaining structural integrity through integrated FEA analysis while significantly increasing productivity compared to manual methods that must be repeated for each component type

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables efficient and optimal powder removal from additively manufactured components, reducing manual labor and improving structural integrity by determining the most effective powder removal pathways and features during the design phase.

Implementation Method 1

AM processes such as powder bed fusion (PBF) use a laser or electron beam to melt and fuse together cross-sections of the layers of powdered material

Methodology Applied

Scientific EffectLaser melting: Laser

Implementation Method 2

AM processes such as powder bed fusion (PBF) use a laser or electron beam to melt and fuse together cross-sections of the layers of powdered material

Methodology Applied

Scientific EffectSelective laser sintering: Selective Laser Sintering

Implementation Method 3

a deflector configured to apply the energy beam to fuse the powder

Methodology Applied

Scientific EffectBeam deflection:

Data Source

PatentUS11292058B2Apparatus and methods for optimization of powder removal features in additively manufactured components

Publication Date: 2022.04.05 DIVERGENT TECHNOLOGIES INC

AI summary

Techniques for optimizing powder hole removal are disclosed. In one aspect, an apparatus for inserting powder removal features may identify what powder removal features are optimal for a given AM component, as well as the optimal location and physical characteristics of these features. The features are automatedly added to the component, and an FEA test is run. In the event of failure, the offending feature is removed and the process is repeated. If successful then the loose powder may be removed in a post-processing step following AM.