Additive Manufacturing Core-Shell Bead Resolution Strategy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufactured object production methods face challenges in achieving high surface accuracy and efficient production time, particularly when weld beads are set to have varying resolutions.
Innovation Solution
The method involves a core portion forming step where first weld beads with a lower resolution are stacked to form the inner portion of the additive manufactured object, followed by a shell portion forming step where second weld beads with a higher resolution are stacked on the surface of the core portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If weld beads are set to have a large width (low resolution), then production time is reduced, but surface accuracy deteriorates and finishing processing time increases
Solution Approach 1:
The additive manufactured object is divided into a core portion and a shell portion. The core portion is formed by stacking weld beads at a first resolution (lower resolution, larger weld bead width), while the shell portion is formed by stacking weld beads at a second resolution (higher resolution, smaller weld bead width). This segmentation allows different regions of the object to have different resolutions, thereby reducing overall production time while maintaining high surface accuracy in the visible shell portion.
2Manufacturing precision
If weld beads are set to have a small width (high resolution), then surface accuracy is improved, but production time increases
Solution Approach 1:
Different regions of the additive manufactured object are assigned different quality levels (resolutions). The shell portion, which forms the outer surface and is visible, is produced with high resolution (small weld bead width) to ensure high surface accuracy. The core portion, which is internal and not visible, is produced with lower resolution (larger weld bead width) to reduce production time. This local quality differentiation optimizes the balance between surface accuracy and production time.
3Manufacturing precision
If uniform high-resolution weld beads are used throughout the object, then surface accuracy is improved, but overall production time increases significantly
Solution Approach 1:
The object is segmented into core and shell portions with different resolution requirements. The core portion uses lower resolution weld beads while the shell portion uses higher resolution weld beads, avoiding the need to produce the entire object at high resolution and thereby significantly reducing overall production time while maintaining surface accuracy.
Solution Approach 2:
High resolution is applied locally only to the shell portion where surface accuracy is critical, while the core portion uses lower resolution. This localized quality approach ensures surface accuracy where needed without incurring the production time penalty of uniform high-resolution production throughout the entire object.
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 the surface accuracy of the additive manufactured object, reduces the need for extensive finishing processing, and shortens the overall production time compared to methods that use uniform high-resolution weld beads throughout.
Implementation Method 1
a method of producing an additive manufactured object by stacking weld beads obtained by melting and solidifying molten filler material
Data Source
AI summary
An additive manufactured object production method includes: a core portion forming step of additively forming a core portion as an inner portion of an additive manufactured object by stacking first weld beads each size of which is corresponding to a first resolution; and a shell portion forming step of additively forming a shell portion as an outer portion of the additive manufactured object on a surface of the core portion by stacking second weld beads each size of which is corresponding to a second resolution higher than the first resolution after the core portion forming step.