Build Plate Integrated Additive Component for Aircraft
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Solution Overview
Problem
Existing manufacturing methods for aircraft components, such as gas turbine engines and aircraft bodies, lack efficiency and complexity in integrating support structures and monolithic bodies.
Innovation Solution
An additive manufacturing process is used to build components layer-by-layer onto a build plate, which is then machined to form a monolithic body including a support structure that integrates the gas turbine engine and aircraft body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used to produce gas turbine engines and aircraft body components separately, then each component can be manufactured with established processes, but the assembly requires multiple mechanical connections and is complex
Solution Approach 1:
The patent merges the gas turbine engine and aircraft body components into a single monolithic structure manufactured using additive manufacturing. The build plate serves as both the support structure and an integral part of the aircraft body, eliminating the need for separate support structures and mechanical connections between components.
Solution Approach 2:
The build plate is designed to serve multiple functions: it acts as the support structure during manufacturing, becomes an integral structural component of the aircraft body, and provides sealing and shielding functions. This multi-functionality reduces the number of separate components needed.
2Ease of operation
If separate support structures are used to hold the gas turbine engine in the aircraft body, then the engine can be positioned correctly, but additional mechanical connections and assembly steps are required
Solution Approach 1:
The support structure is merged with the aircraft body as a single integrated component. The build plate is positioned within the aircraft body cavity and becomes part of the structural framework, eliminating the need for separate support structures and reducing assembly steps.
3Adaptability or versatility
If multiple components are assembled to form the aircraft structure, then design flexibility is maintained, but sealing and shielding require additional mechanical connections
Solution Approach 1:
Multiple components are merged into a monolithic structure where the build plate and aircraft body form a single sealed volume. This integration ensures reliable sealing and shielding without requiring additional mechanical connections between separate components.
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 method enables the creation of complex, integrated aircraft components with reduced mechanical connections, simplified design, and improved sealing/shielding, enhancing the structural integrity and efficiency of aircraft assemblies.
Implementation Method 1
selectively solidifying the first layer of powder using an energy beam to form a first portion of the first object that is fused to the build plate
Implementation Method 2
selectively solidifying the first layer of powder using an energy beam
Implementation Method 3
selectively solidifying the second layer of powder using the energy beam to form a second portion of the first object that is fused to the first portion of the first object
Data Source
AI summary
During a formation method, a build plate is arranged within a build space. A first object is built onto the build plate within the build space using an additive manufacturing process. The object is fused to the build plate during the additive manufacturing process. At least the build plate is machined to form a component that includes a portion of the build plate and at least a portion of the first object.