Cylindrical Substrate Additive Manufacturing for Complex 3D Shapes
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Solution Overview
Problem
Current additive manufacturing techniques primarily use Cartesian coordinate systems, lacking systems that effectively implement powder-based additive manufacturing in cylindrical coordinate systems, which are necessary for building complex shapes and structures.
Innovation Solution
A system and method utilizing a cylindrically-shaped substrate rotated relative to a powder source, with a fusion/binder source controlled by a computing system to deposit and fuse powder material in radial layers, allowing three-dimensional objects to be built in a cylindrical coordinate system according to a CAD model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional Cartesian coordinate system additive manufacturing is used, then the manufacturing process is simple and well-established, but the ability to build complex shapes and structures is limited
Solution Approach 1:
The patent applies cylindrical coordinate system geometry to enable additive manufacturing of complex shapes. The system uses a cylindrical substrate that rotates during the manufacturing process, allowing material deposition in radial, circumferential, and axial directions. This curved coordinate system approach enables creation of complex three-dimensional objects with arbitrary shapes that cannot be easily formed using traditional Cartesian layer-by-layer printing methods.
2Adaptability or versatility
If powder-based additive manufacturing is used with cylindrical coordinate system, then complex three-dimensional objects can be created, but the system complexity increases compared to traditional methods
Solution Approach 1:
The patent integrates multiple functions into a unified additive manufacturing system. The cylindrical substrate serves as both the form tool and the rotating workpiece. The system combines powder material deposition, selective bonding, and rotational motion control into a single integrated process. The computing system coordinates all movements and material deposition in real-time, enabling multi-functional operation within one device configuration.
Solution Approach 2:
The system employs dynamic rotation of the cylindrical substrate during the additive manufacturing process. The substrate rotates at controlled speeds while material is deposited in radial and circumferential directions. This dynamic motion enables the formation of complex three-dimensional structures by progressively building layers in the cylindrical coordinate system, allowing the system to adapt to various object geometries through programmed motion patterns.
3Manufacturing precision
If material is deposited in radial layers on rotating substrate, then cylindrical coordinate system manufacturing is achieved, but the deposition process becomes more complex
Solution Approach 1:
The computing system in the patent provides real-time feedback control for the additive manufacturing process. It monitors the rotation position, material deposition rate, and bonding status to ensure precise alignment in the cylindrical coordinate system. The system adjusts deposition parameters dynamically based on feedback from sensors, maintaining accurate radial and circumferential positioning throughout the manufacturing process.
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 creation of complex three-dimensional objects with arbitrary shapes by selectively fusing powder material in radial layers, addressing the need for powder-based additive manufacturing in cylindrical coordinate systems and allowing for the formation of non-cylindrical and complex profiles.
Implementation Method 1
a fusion/binder source configured to cause the powder material deposited relative to the substrate to be fused or adhered together
Implementation Method 2
a fusion/binder source configured to cause the powder material deposited relative to the substrate to be fused or adhered together
Data Source
AI summary
In one aspect, a system for building three-dimensional objects includes a powder source containing a powder material and a cylindrically-shaped substrate rotatable about a rotational axis. The substrate is provided in operative association with the powder source such that rotation of the substrate relative to the powder source about the rotational axis results in a layer of powder material being deposited relative to at least a portion of an outer surface of the substrate. The system also includes a fusion/binder source configured to cause the powder material deposited relative to the substrate to be fused or adhered together, and a computing system configured to control an operation of the fusion/binder source as the substrate is rotated about the rotational axis to generate a three-dimensional object relative to the outer surface of the substrate.