As-Deposited Data Model for Machining Additive Blanks
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Solution Overview
Problem
Current additive manufacturing processes, such as Laser Powder Bed Fusion, Electron Beam Melting, and Selective Laser Sintering, face limitations including high costs, low deposition rates, and toolpath generation challenges, which hinder widespread adoption due to expensive equipment, material costs, and the need for skilled operators to manage complex toolpaths.
Innovation Solution
A non-continuous deposition method that uses discrete increments of material to form a three-dimensional object, where material is deposited in voxel spaces defined by a digital model, allowing for a coarse outer shape to be created and subsequently machined into a final form, reducing costs and complexity by utilizing standard GMAW processes and modular scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If Laser Powder Bed Fusion, Electron Beam Melting, or Selective Laser Sintering are used, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses consumable wire electrodes in arc-based additive manufacturing processes, replacing expensive reusable laser systems and powder handling equipment. The wire electrode serves as both the deposition tool and material source, eliminating the need for separate laser sources, powder feeders, and complex motion control systems required by LPBF and EBM
Solution Approach 2:
The patent replaces complex laser-based thermal processing systems with simpler arc-based melting processes. The arc welding mechanism provides controlled heating and material deposition without requiring precision laser optics, powder delivery systems, or complex atmospheric control, thereby reducing device complexity while maintaining manufacturing capability
2Manufacturing precision
If Laser Powder Bed Fusion, Electron Beam Melting, or Selective Laser Sintering are used, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent changes the fundamental processing parameters by using arc-based heating instead of laser heating, enabling higher deposition rates. The arc process allows for greater energy input and faster material accumulation, achieving productivity improvements while maintaining acceptable precision through subsequent machining operations
Solution Approach 2:
The patent segments the manufacturing process into two distinct phases: additive manufacturing for rapid bulk material deposition and subsequent machining for precision finishing. This segmentation allows each process to operate at its optimal speed and quality level, with the additive phase providing high productivity and the machining phase providing high precision
3Manufacturing precision
If Directed Energy Deposition with fine powder is used, then manufacturing precision is improved, but loss of substance increases
Solution Approach 1:
The patent changes the material feedstock from fine powder to wire form, fundamentally altering the deposition parameters. Wire-based deposition eliminates the 10-50% powder loss inherent in powder-based DED processes, as wire material is directly fed into the arc with minimal waste, while still achieving precise dimensional control through the as-deposited data model guidance
4Device complexity
If Wire Arc Additive Manufacturing with robotic systems is used, then device complexity and cost are reduced, but manufacturing precision decreases
Solution Approach 1:
The patent segments the manufacturing process into additive manufacturing for bulk material deposition followed by machining for precision finishing. This segmentation allows the use of simpler robotic arc welding systems for the additive phase, accepting lower surface quality, while the subsequent machining phase restores high precision and surface finish
Solution Approach 2:
The patent performs preliminary additive manufacturing to create a near-net-shape blank with the as-deposited data model, preparing the workpiece in advance for final precision machining. This preliminary action removes the need for highly precise robotic motion control during deposition, as the final precision is achieved in the subsequent machining 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 costs and increases industrial reliability, enabling high-throughput, low-cost additive manufacturing by simplifying the manufacturing process and reducing the need for skilled operators, making it more accessible for various applications.
Implementation Method 1
material is deposited in discrete increments at specification locations in the build space in conformance to a first digital data model
Implementation Method 2
utilizing standard arc welding processes such as Gas Metal Arc Welding (GMAW)
Data Source
AI summary
In the context of additive manufacturing processes wherein objects are built by layered accumulations of discrete instantaneous deposits of feedstock material at specific locations according to a first three-dimensional digital data model, processes and systems are provided for first forming an oversized blank part that roughly conforms to the first model and is subsequently machined to final dimensions specified by the first model. Various embodiments provide for generating a second model representing the expected shape of the blank part, as formed by a discrete deposition process, and facilitating calculation of specific toolpaths by which material removal tools may render the final shape.