Additive Manufacturing Build Characteristic Contribution Profiles
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Solution Overview
Problem
Existing additive manufacturing systems lack localized control over build characteristics, leading to undesirable anomalies such as stress and deformation in components, as altering build parameters for one region can affect the entire component, resulting in suboptimal performance.
Innovation Solution
An additive manufacturing system with a build characteristic contribution evaluation module that generates a model with regions of interest, applies strain loads to elements, and determines build parameters based on build characteristic contribution profiles to control specific areas of the component, allowing for precise adjustment of build characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If build parameters are modified for the entire component or region of interest based on evaluated models, then areas of high stress or deformation can be located, but the build characteristics of the entire component are adversely affected with increased stress or deformation in the region of interest
Solution Approach 1:
The patent divides the component into discrete elements and calculates a build characteristic contribution profile for each element, showing its individual contribution to stress or deformation in the region of interest. This segmentation enables selective modification of build parameters for only those elements that significantly contribute to the problem, rather than modifying parameters for the entire component. The contribution profile identifies specific elements with high contribution values that can be targeted for parameter adjustment, thereby resolving the contradiction by achieving precise local control without globally affecting component quality.
Solution Approach 2:
The patent implements local quality by determining modified build parameters specifically for elements identified in the build characteristic contribution profile as having high contribution to stress or deformation. Instead of applying uniform parameter modifications across the entire component, the system applies localized parameter changes only to specific elements where needed. This localized approach allows precise control of build characteristics in problematic regions while maintaining optimal parameters for the rest of the component, thus improving reliability without sacrificing manufacturing precision.
2Manufacturing precision
If build parameters are altered to influence build characteristics in a region of interest, then desired anomalies can be formed or high stress areas identified, but the build characteristics of other regions are adversely affected
Solution Approach 1:
The build characteristic contribution profile segments the component into individual elements with quantified contributions to build characteristics. This segmentation enables the system to identify and target only specific elements for parameter modification, preserving the adaptability to adjust parameters locally without forcing global changes. The profile allows flexible, element-specific parameter control while maintaining the ability to adapt to different regional requirements throughout the component.
Solution Approach 2:
The patent applies partial action by modifying build parameters for only those elements that contribute significantly to the build characteristics of the region of interest, rather than applying modifications to the entire component. The build characteristic contribution profile identifies the subset of elements requiring parameter adjustment, allowing the system to exert control precisely where needed while leaving other elements unchanged. This partial approach maintains build parameter flexibility for targeted regions without adversely affecting other areas.
3Productivity
If conventional additive manufacturing systems are used without build characteristic contribution profiles, then components can be fabricated, but localized control of build characteristics is not achieved resulting in undesirable anomalies
Solution Approach 1:
The build characteristic contribution profile serves as a feedback mechanism that evaluates each element's contribution to stress, deformation, or other build characteristics in the region of interest. This feedback information guides the determination of modified build parameters for specific elements. The system uses this feedback to iteratively optimize build parameters, achieving both high manufacturing precision through localized control and maintained productivity by avoiding unnecessary parameter changes across the entire component.
Solution Approach 2:
The patent performs preliminary action by calculating the build characteristic contribution profile before actual component fabrication. This pre-fabrication analysis identifies which elements will contribute to undesirable build characteristics, allowing the system to predetermined modified build parameters for those elements. By performing this analysis in advance, the system ensures manufacturing precision is optimized before production begins, while maintaining productivity through efficient pre-planning rather than iterative adjustments during manufacturing.
Data Source
AI summary
An additive manufacturing system includes a control system communicatively coupled to a consolidation device and configured to control operation of the consolidation device. The control system is configured to generate a model of a component including a plurality of elements and at least one region of interest. The control system is also configured to apply at least one strain load to at least one element of the plurality of elements and generate a build characteristic contribution profile based on the at least one strain load. The control system is further configured to determine a build parameter based at least partly on the build characteristic contribution profile.