Hybrid Cast Housing for Complex Features Without Custom Molds

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Solution Overview

Problem

Existing casting technologies face challenges in efficiently and cost-effectively producing components with intricate features and complex structures, leading to long lead times and high costs due to the need for custom molds and limited control over material properties.

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 components with complex features and improved material properties without heating the material to its melting point, thereby reducing costs and assembly times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a custom mold is used to create a component with specific structure, then the component achieves the desired shape and structure, but the cost and lead time for preparing the mold increase significantly

Engineering Contradiction:

Improvecomponent structureVSAvoidlead time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The component is divided into two parts: a cast body formed by traditional molding and additional features deposited by additive manufacturing. This segmentation allows the base structure to be produced by mold while complex features are added later, reducing the complexity requirements for the mold itself.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cast body with basic structure is prepared in advance using traditional casting, and then additional features are deposited afterward using additive manufacturing. This preliminary action allows the mold to focus only on creating the base structure, reducing mold complexity and preparation time.

Inventive Principle:

Principle #10Preliminary action

2Shape

If a custom mold is prepared for each component design, then the component achieves its specific structure, but the cost increases prohibitively

Engineering Contradiction:

Improvecomponent structureVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The manufacturing process is segmented into casting for the base structure and additive manufacturing for additional features. This allows the mold to be simpler and reused for the cast body, while the complex features are added through a different process that doesn't require mold modifications.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different manufacturing methods are applied to different parts of the component: traditional casting for the bulk structure and additive manufacturing for specific features requiring complex geometry. This local application of manufacturing techniques optimizes both cost and structural requirements.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If the material is heated to melting temperature for additive manufacturing, then the material can be deposited, but the energy consumption increases and material properties may be compromised

Engineering Contradiction:

Improvedeposition processVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The additive manufacturing process uses solid state deposition where material is transformed without reaching melting temperature. This parameter change in the phase transition process reduces energy consumption while maintaining deposition capability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The thermal field used in traditional melting-based additive manufacturing is replaced with a solid state deformation mechanism. Material is deposited through mechanical pressure and phase transformation below melting point, substituting thermal energy with mechanical energy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 the efficient and cost-effective fabrication of components with complex features and improved material properties, reducing overall process complexities and lead times, while providing unprecedented control over material properties at different locations.

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

PatentEP4194123A1Housing and method of preparing same using a hybrid casting-additive manufacturing process

Publication Date: 2023.06.14 LOCKHEED MARTIN CORP

Figure 1
Figure 2A~2B
Figure 2C

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.