DED Compression Rig With Thermal Feedback for Dense Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current Directed Energy Deposition (DED) systems face challenges in integrating compression into the additive manufacturing process simultaneously with material deposition, leading to increased processing time and inability to produce components with forging-like qualities due to sequential deposition and compression phases.
Innovation Solution
The implementation of a DED system that combines a deposition head with a compression rig, allowing for simultaneous material deposition and compression using a compression head with temperature and distance sensors to adjust the position and load applied, enabling continuous compressive loading during deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compression is applied after material deposition in sequential phases, then the component achieves desired density and structural integrity, but the total processing time increases significantly
Solution Approach 1:
The patent combines the deposition head and compression rig into a single integrated system, allowing both material deposition and compression to occur simultaneously during the same operational cycle. This eliminates the sequential waiting time between deposition and compression phases, directly resolving the time-loss contradiction while maintaining component density requirements.
Solution Approach 2:
The system enables continuous compression action during the entire deposition process by positioning the compression head to follow the deposition head's movement. The compression force is applied continuously to each layer as it is deposited, eliminating idle time between phases and maintaining productive action throughout the manufacturing cycle.
2Loss of time
If compression is applied simultaneously with material deposition, then processing time is reduced, but the temperature control and compression consistency become more difficult to maintain
Solution Approach 1:
The system incorporates temperature sensors that continuously monitor the temperature of the deposited material in real-time. This feedback is transmitted to the controller, which dynamically adjusts the compression force and deposition parameters to maintain optimal temperature ranges, ensuring consistent compression quality despite the simultaneous operation.
Solution Approach 2:
The compression force is made dynamic rather than static, with the system continuously adjusting the compression magnitude based on real-time temperature and deposition rate measurements. This dynamic adaptation allows the system to maintain reliable temperature control while operating in the time-efficient simultaneous mode.
3Ease of manufacture
If a fixed build table with separate compression apparatus is used, then the deposition and compression functions are well-defined, but the system complexity and space requirements increase
Solution Approach 1:
The build table is designed with multi-functionality, serving both as the deposition surface and as part of the compression mechanism. The same robotic positioning system controls both the deposition head and compression head, allowing a single system to perform multiple functions without requiring separate dedicated apparatus for each operation.
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 consistent temperature for optimal compression, 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
a pair of temperature sensors positioned on opposite sides of the top roller and detecting a temperature of the top surface of the component
Implementation Method 2
DED apparatuses use a focused energy source, such as a laser or electron beam, to melt the feedstock material
Implementation Method 3
a compression rig including a compression head supporting a top roller configured to apply a compressive load onto a top surface of the component
Data Source
AI summary
An additive manufacturing system for forming a component including a compression rig including a compression head supporting a top compression device applying a compressive load onto a top surface of the component, a pair of temperature sensors positioned on opposite sides of the top compression device and detecting a temperature of the top surface of the component, and a pair of distance sensors positioned on opposite sides of the top compression device and detecting a distance to the top surface of the component, and a controller configured to adjust a position of the compression rig and a load applied by the top compression device based on at least one of the detected temperatures and distances.