Dynamic Bead Spacing for Variable-Width Metal AM Infill
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Solution Overview
Problem
Conventional additive manufacturing processes are inefficient in filling build layers, especially when the width of the build layer varies, leading to long build times and inadequate infill techniques for certain types of parts.
Innovation Solution
The system dynamically adjusts the weave width, frequency, dwell, and travel speed of a beaded weave pattern during metal deposition to match the varying width of the build layer, using a computer-controlled metal deposition apparatus and robot to maintain a constant deposition rate and contact tip-to-work distance, allowing for efficient infilling of 3D parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional additive manufacturing processes are used to fill build layers, then parts can be manufactured layer-by-layer, but build times become long and infill techniques are inadequate for parts with varying layer widths
Solution Approach 1:
The system dynamically adjusts bead spacing and weave pattern parameters during deposition to adapt to varying build layer widths. The bead spacing is modified in real-time based on the current layer width, allowing the infill process to maintain optimal quality across different geometries while improving overall build efficiency
Solution Approach 2:
The invention changes multiple deposition parameters simultaneously including bead spacing, weave frequency, and travel speed to optimize both productivity and precision. By adjusting these parameters dynamically during the build process, the system achieves faster build times while maintaining adequate infill quality for parts with varying layer widths
2Ease of operation
If bead spacing is kept constant during deposition, then the deposition process is simple to control, but the bead width cannot adapt to varying build layer widths
Solution Approach 1:
The system transitions from static bead spacing to dynamic bead spacing that automatically adjusts during deposition. The bead spacing is modified based on the current build layer width, enabling the process to handle varying geometries effectively while maintaining automated control through computer-based systems
Solution Approach 2:
The system incorporates feedback mechanisms where the build layer dimensions are continuously monitored and used to adjust bead spacing parameters. This closed-loop control allows the deposition process to automatically adapt to varying layer widths while maintaining precise control through computer-based regulation
3Stability of the object's composition
If the deposition process uses fixed parameters, then the process is stable and easy to maintain, but it cannot efficiently fill build layers with varying widths
Solution Approach 1:
The invention implements dynamic parameter adjustment that maintains process stability through automated control systems. By continuously adapting bead spacing and deposition parameters based on real-time measurements of build layer width, the system achieves both stability and improved infill efficiency for varying geometries
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 enables efficient and precise filling of build layers with a dynamically varying bead width, reducing build times and improving the quality of additively manufactured parts by adapting to the changing layer width, thus overcoming the limitations of conventional methods.
Implementation Method 1
a power source configured to provide energy to melt at least the consumable wire electrode during the deposition of the beaded weave pattern by forming an arc between the consumable wire electrode and the 3D part
Implementation Method 2
a laser operatively connected to the power source. The power source and the laser are configured to provide energy in the form of a laser beam to melt at least the filler wire during the deposition of the beaded weave pattern
Data Source
AI summary
Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a computer control apparatus accesses multiple planned build patterns corresponding to multiple build layers of a three-dimensional (3D) part to be additively manufactured. A metal deposition apparatus deposits metal material to form at least a portion of a build layer of the 3D part. The metal material is deposited as a beaded weave pattern, based on a planned path of a planned build pattern, under control of the computer control apparatus. A weave width, a weave frequency, and a weave dwell of the beaded weave pattern may be dynamically adjusted during deposition of the beaded weave pattern. The adjustments are under control of the computer control apparatus based on the planned build pattern, as a width of the build layer varies along a length dimension of the build layer.