Deposition Control Plate Apertures for Additive Manufacturing

Solution Overview

Problem

Additive layer manufacturing is expensive and time-consuming due to the excessive use of material and inefficient deposition processes.

Innovation Solution

The use of a deposition control plate with apertures to restrict material deposition to specific areas and an energy source for selective melting, reducing material usage and improving the efficiency of the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If material is deposited over the entire build area in additive layer manufacturing, then complete coverage is achieved, but material waste increases and process time extends

Engineering Contradiction:

Improvematerial wasteVSAvoidprocess time

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The build area is segmented into multiple deposition zones corresponding to different object regions. The deposition control plate divides the build chamber into multiple zones, allowing material to be deposited only in specific areas where object features are present, rather than covering the entire build area uniformly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Material deposition is applied locally only where required by the object geometry. The deposition control plate enables different regions of the build area to receive material selectively based on the local requirements of the object being manufactured, avoiding unnecessary material deposition in empty or already-formed regions.

Inventive Principle:

Principle #3Local quality

2Loss of substance

If material is deposited over the entire build area, then uniform coverage is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvematerial usage volumeVSAvoidmanufacturing cost

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The build area is segmented into multiple deposition zones corresponding to different object regions. The deposition control plate divides the build chamber into multiple zones, allowing material to be deposited only in specific areas where object features are present, rather than covering the entire build area uniformly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Material deposition is applied locally only where required by the object geometry. The deposition control plate enables different regions of the build area to receive material selectively based on the local requirements of the object being manufactured, avoiding unnecessary material deposition in empty or already-formed regions.

Inventive Principle:

Principle #3Local quality

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 the volume of material required and enhances the speed and efficiency of the additive layer manufacturing process, making it more cost-effective and time-efficient.

Implementation Method 1

one or more apertures in the deposition control plate restrict deposition of material to one or more deposition areas

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

selectively melting the selectively deposited material

Methodology Applied

Scientific EffectSelective melting: Melting

Data Source

PatentUS9962766B2Method and apparatus for making an object

Publication Date: 2018.05.08 ROLLS ROYCE PLC

AI summary

A method and apparatus for making an object comprising repeatedly selectively depositing a material by controlling one or more deposition areas using a deposition control plate comprising one or more apertures and selectively melting the selectively deposited material.