Hybrid Cast Housing for Complex Features Without Custom Mold Delays

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Solution Overview

Problem

Existing casting technologies face challenges in efficiently producing components with intricate features and complex structures due to high costs and long lead times, as well as limitations in material control and reproducibility, particularly when minor design changes are required.

Innovation Solution

A hybrid casting-additive manufacturing process that combines a cast body formed by a mold with features deposited using solid state additive manufacturing, allowing for the creation of complex structures without heating the material to its melting point, enabling improved material properties and reduced costs through selective deposition of materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional casting with custom molds is used to create components with specific structures, then manufacturing precision and structural accuracy are improved, but cost and lead time increase significantly

Engineering Contradiction:

Improvestructural accuracyVSAvoidlead time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The manufacturing process is divided into two distinct stages: (1) casting the base component structure using traditional mold methods to achieve high structural accuracy, and (2) adding intricate features through additive manufacturing. This segmentation allows each process to optimize for its strength while avoiding its weaknesses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base component structure is cast in advance using traditional methods to establish the primary geometry and structural integrity. Subsequently, additive manufacturing is used to add final features, allowing the main structure to be prepared ahead of time without waiting for complete feature fabrication.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If traditional casting with custom molds is used to create components with specific structures, then manufacturing precision and structural accuracy are improved, but cost increases significantly

Engineering Contradiction:

Improvestructural accuracyVSAvoidcost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Different manufacturing methods are applied to different regions of the component: traditional casting is used for the base structure where high dimensional accuracy is critical, while additive manufacturing is used for intricate features where mold complexity would be prohibitively expensive. This local quality approach optimizes cost-efficiency for each region.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent merges two previously separate manufacturing processes (traditional casting and additive manufacturing) into a single hybrid workflow. The cast component serves as the substrate for additive features, creating an integrated part that leverages the strengths of both methods while reducing overall cost.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If solid state additive manufacturing is used to deposit features on cast body, then adaptability for design changes is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedesign change flexibilityVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The base component geometry is created using traditional casting methods to establish the primary form. Additive manufacturing then adds features by depositing material layer-by-layer to build up the final geometry, effectively copying and augmenting the base structure with design-specific features that are easier to modify.

Inventive Principle:

Principle #26Copying

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 enhances throughput and efficiency, reduces assembly times and costs, and provides unprecedented control over material properties, enabling the fabrication of components with complex features and internal passageways, while minimizing galvanic corrosion and weight.

Implementation Method 1

depositing at least one feature on the cast body using a solid state additive manufacturing process in which a melting temperature of a material of the at least one feature is not reached

Methodology Applied

Scientific EffectSolid state additive manufacturing: 3D Printing

Data Source

PatentUS11878343B2Housing and method of preparing same using a hybrid casting-additive manufacturing process

Publication Date: 2024.01.23 LOCKHEED MARTIN CORP

AI summary

The present disclosure is directed, in certain embodiments, a component of a mechanical apparatus. The component includes a cast body with an initial structure formed by a mold and at least one feature deposited on the cast body using a solid state additive manufacturing process, such that in combination the initial structure and the at least one feature form a complete structure of the component.