DED Compression Rig for Continuous Deposition Densification
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Solution Overview
Problem
Current DED additive manufacturing systems require sequential deposition and compression phases, leading to increased processing time and uneven microstructure due to compression applied on variable temperature material layers, preventing the production of components with forging-like qualities.
Innovation Solution
A DED system that integrates a rotary build table and a compression rig allowing simultaneous deposition and compression phases, with a controller managing the application of compressive loads during material deposition to maintain constant temperature and improve microstructure homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential deposition and compression phases are used, then equipment complexity is reduced, but processing time increases and microstructure uniformity deteriorates
Solution Approach 1:
The patent combines the deposition head and compression rig into a single integrated system that performs both material deposition and compression operations simultaneously. The deposition head includes both the material delivery nozzle and the compression apparatus, allowing these two previously separate processes to occur in parallel on the same material layer, thereby reducing total processing time without requiring multiple separate equipment systems
2Manufacturing precision
If compression is applied after deposition, then equipment complexity is reduced, but microstructure uniformity deteriorates due to variable temperature material
Solution Approach 1:
The patent implements continuous compression action during the deposition process itself, rather than waiting for deposition to complete. The compression apparatus applies force to the material layer continuously as it is being deposited, maintaining constant temperature conditions throughout the process. This continuous action ensures uniform microstructure by eliminating the temperature variations that occur when compression is delayed until after deposition
3Productivity
If simultaneous deposition and compression are integrated, then processing time is reduced, but device complexity increases
Solution Approach 1:
The deposition head is designed as a multi-functional apparatus that simultaneously performs material delivery and compression operations. The same mechanical structure serves dual purposes: the deposition nozzle delivers material while the integrated compression apparatus applies compressive force to the deposited layer. This universal design allows one component to perform multiple functions that would traditionally require separate equipment, reducing overall system complexity despite the advanced functionality
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 reduces processing time, ensures compressive loads are applied at a consistent temperature, and enables the production of components with forge-like qualities by integrating compression into the deposition process without significant time or cost additions.
Implementation Method 1
The feedstock material is melted as it exits the deposition nozzle
Implementation Method 2
a compression rig positioned proximate the deposition assembly and having a compression head operable to continuously apply a compressive load to deposited melted feedstock material during deposition of the melted feedstock material
Data Source
AI summary
A directed energy deposition (DED) additive manufacturing system may be utilized for manufacturing a cylindrical component from a feedstock material. The DED additive manufacturing system may comprise a rotary build table, a deposition assembly for depositing melted feedstock to form the component upon rotation of the build table, and a compression rig positioned proximate the deposition assembly and operable to continuously apply a compressive load to deposited melted feedstock material during deposition of the melted feedstock material.