Circular Modular Tray for Faster Powder Bed Part Separation
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Solution Overview
Problem
The existing methods for manufacturing parts with an axis of revolution on a powder bed in additive manufacturing face challenges such as time-consuming separation from the tray using saw cutting or EDM, which exposes metal parts to corrosion risks.
Innovation Solution
A circular modular tray composed of concentrically coupled modules with features for easy placement on a lathe, allowing integrated separation during machining operations, eliminating the need for separate cutting steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a square or rectangular tray is used for additive manufacturing of parts with an axis of revolution, then the manufacturing process can be completed, but additional separation operations (saw cutting, EDM) are required which increase manufacturing time and expose metal parts to corrosion risks
Solution Approach 1:
The tray is divided into modular segments that can be easily separated from the manufactured part. The modular design allows the tray to be broken down into smaller sections that can be removed without requiring complex cutting operations, thus reducing separation time and manual intervention.
Solution Approach 2:
Instead of designing a traditional square/rectangular tray that requires post-manufacturing separation, the invention inverts the approach by using a circular tray geometry that aligns with the axis of revolution of the part. This allows the part to be directly separated from the tray during or after the additive manufacturing process without requiring additional cutting operations.
2Ease of operation
If saw cutting or EDM is used to separate the part from the tray, then the part can be removed, but metal parts are exposed to corrosion risks during these operations
Solution Approach 1:
The invention reverses the traditional approach by designing a circular tray that matches the axis of revolution of the part. This allows the part to be separated from the tray through a simple rotational extraction process rather than requiring corrosive cutting methods like saw cutting or EDM, thereby eliminating corrosion risks during separation.
Solution Approach 2:
The tray is designed as a disposable or easily replaceable component. Instead of using durable trays that require complex separation processes, the invention employs trays that can be discarded or quickly replaced after a single use, eliminating the need for separation operations that expose metal parts to corrosion.
3Productivity
If a circular modular tray is used for additive manufacturing of parts with an axis of revolution, then separation during machining is enabled, but the tray design becomes more complex
Solution Approach 1:
The circular tray is divided into modular segments that can be independently manufactured and assembled. This segmentation simplifies the overall design complexity by breaking down the tray into standardizable components while maintaining the circular geometry needed for efficient separation during machining operations.
Solution Approach 2:
The circular modular tray design serves multiple functions: it provides the necessary support during additive manufacturing, aligns with the axis of revolution of the part, and enables direct separation during machining operations. This multi-functionality justifies the slightly increased design complexity by eliminating the need for separate separation fixtures or operations.
Data Source
AI summary
A circular modular tray for the additive manufacturing of a part with an axis of revolution on a powder bed, characterised in that it consists of an assembly of modules that are concentrically coupled along a contiguous axis in a radial direction, the modules including an annular peripheral module and a circular central module.