Build Plate Inserts for Thermal Stress Relief in Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing processes face challenges with thermally induced stresses and deformation in printed parts and build plates due to differential thermal expansion, leading to residual stress, part deformation, and increased handling difficulties with large and heavy build plates.
Innovation Solution
The use of removable inserts within recesses in the build plate allows for thermal expansion and contraction, reducing residual stress and deformation by distributing thermal stresses away from the build plate, enabling easier part separation and build plate reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material is deposited and melted on the build plate surface, then parts are formed through additive manufacturing, but thermally induced stresses and deformations occur due to differential thermal expansion
Solution Approach 1:
The build plate is segmented by incorporating removable inserts within recesses, separating the build surface from the main build plate structure. This allows the insert to expand and contract independently during thermal cycles, reducing residual stress and deformation in printed parts while maintaining manufacturing precision.
Solution Approach 2:
The insert material is selected to have thermal expansion properties that match or complement the printed part material. By changing the thermal parameters of the build surface through material selection, the differential thermal expansion between the part and build plate is minimized, reducing residual stresses and deformations.
2Area of stationary object
If build plates are made large to accommodate bigger parts, then manufacturing capability is improved, but handling difficulties and weight increase
Solution Approach 1:
The build plate system is segmented into a main build plate and removable inserts. This allows the build plate to be optimized for structural integrity while the inserts provide the necessary build area, reducing the overall size and weight of the build plate while maintaining the ability to manufacture large parts.
Solution Approach 2:
The build surface is extracted from the main build plate structure and implemented as removable inserts. This separation allows the build plate to be smaller and lighter, improving ease of handling, while the inserts can be optimized for the specific build area required for each manufacturing task.
3Productivity
If build plates are reused multiple times, then resource efficiency is improved, but residual stresses accumulate leading to reduced performance
Solution Approach 1:
The inserts are designed to be removable and replaceable after a certain number of uses or when performance degrades. This allows the main build plate to be reused indefinitely while the inserts are periodically replaced, maintaining high productivity without cumulative stress damage to the build plate itself.
Solution Approach 2:
By segmenting the build surface into removable inserts, the patent isolates the wear and stress accumulation to the inserts rather than the entire build plate. This allows selective replacement of only the worn inserts, preserving the main build plate for continued reuse and maintaining reliability over time.
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 reduces residual thermal stresses and deformations in printed parts and build plates, facilitates faster and easier part removal, and extends the life of build plates by allowing inserts to be refinished and reused, thereby saving time, resources, and storage space.
Implementation Method 1
The insert and the recess are sized and shaped to retain the insert in the recess... allowing for thermal expansion and contraction, reducing residual stress and deformation
Implementation Method 2
one or more laser beams are scanned over a thin layer of metal powder... the delivered energy is sufficient to melt the particles of metal powder, one or more melt pools may be established
Data Source
AI summary
Build plate assemblies and their methods of use for an additive manufacturing system are disclosed. In some embodiments, a build plate assembly may include a build plate with a build surface and one or more recesses formed in the build plate. One or more inserts may be inserted into the corresponding one or more recesses of the build plate such that a portion of the one or more inserts are accessible through one or more corresponding openings formed in the build surface associated with the recesses.