Clad Metal Build Substrate for DED Component Separation
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Solution Overview
Problem
Existing directed energy deposition (DED) technologies require expensive and energy-intensive post-processing techniques, such as bandsaws or wire electro discharge machining, to separate finished components from bulky metallic substrates, occupying valuable space and increasing production costs.
Innovation Solution
A build substrate with a clad metal layer that supports stresses and temperatures during deposition, allowing the article to be fused to the substrate and easily removed without additional cutting equipment, featuring a support substrate with a clad metal layer that can be dissolved or patterned for facilitated separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick and bulky metallic substrate is used to support stresses during deposition, then the substrate can withstand deposition stresses and temperatures, but expensive and energy-intensive post-processing techniques are required to separate the finished component from the substrate
Solution Approach 1:
The substrate is divided into two distinct layers: a support substrate that provides mechanical strength and a clad metal layer that facilitates easy separation. This segmentation allows each layer to perform its specific function optimally - the support substrate withstands deposition stresses while the clad layer enables simple component removal without expensive post-processing equipment
Solution Approach 2:
The separation function is extracted from the bulk substrate material and concentrated into the clad metal layer. This thin clad layer is specifically designed to be removed along with the finished component, leaving the support substrate intact and reusable. This extraction eliminates the need for expensive cutting techniques like bandsaws or wire EDM
2Strength
If a thick and bulky metallic substrate is used to support stresses during deposition, then the substrate can withstand deposition stresses and temperatures, but additional post processing equipment is required which occupies valuable space on the production floor
Solution Approach 1:
The separation function is extracted from the bulk substrate material and concentrated into the clad metal layer. This thin clad layer is specifically designed to be removed along with the finished component, leaving the support substrate intact and reusable. This extraction eliminates the need for expensive cutting techniques like bandsaws or wire EDM
3Strength
If a thick and bulky metallic substrate is used to support stresses during deposition, then the substrate can withstand deposition stresses and temperatures, but the production costs increase due to additional equipment and energy consumption
Solution Approach 1:
The separation function is extracted from the bulk substrate material and concentrated into the clad metal layer. This thin clad layer is specifically designed to be removed along with the finished component, leaving the support substrate intact and reusable. This extraction eliminates the need for expensive cutting techniques like bandsaws or wire EDM
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
Enables the easy removal of finished components from the build substrate without the need for expensive cutting techniques, reducing production costs and space requirements by integrating a support substrate that withstands deposition stresses and temperatures.
Implementation Method 1
The build substrate may be placed in a solvent bath, where the clad metal layer is dissolved
Data Source
AI summary
A build substrate for supporting an article during a directed energy deposition (DED) process includes a clad metal layer defining a build surface, where the article is fused to the build surface during deposition. The build substrate also includes a support substrate configured to support stresses and temperatures experienced during deposition. The support substrate defines an upper surface and a lower surface, and at least a portion of the upper surface of the support substrate is covered with the clad metal layer.