Dynamic Bead Spacing for Variable-Width Metal Additive Manufacturing
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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
An additive manufacturing system and method that dynamically adjusts the weave width, frequency, dwell, and travel speed of a beaded weave pattern during metal deposition, 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 varying build layer widths.
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 widths
Solution Approach 1:
The system dynamically adjusts bead spacing and weave fill parameters during the additive manufacturing process based on real-time detection of build layer width variations. The bead spacing is continuously modified to maintain optimal deposition density across varying layer widths, enabling efficient infilling of complex geometries while maintaining high productivity
Solution Approach 2:
The system incorporates detection mechanisms that monitor build layer width in real-time and provide feedback to the control system. This feedback loop enables automatic adjustment of bead spacing and deposition parameters to adapt to varying layer widths, resolving the contradiction between maintaining consistent infill quality and achieving high build speeds
2Ease of operation
If metal material is deposited as a beaded weave pattern with constant parameters, then deposition process is simple to control, but deposition rate varies when build layer width varies
Solution Approach 1:
The system transitions from static bead spacing to dynamic bead spacing that automatically adjusts during deposition. The bead spacing is modified in real-time based on build layer width detection, ensuring consistent deposition rate and material density across varying layer geometries while maintaining automated control
Solution Approach 2:
The system changes deposition parameters (bead spacing, weave frequency, deposition speed) dynamically during the manufacturing process. When build layer width increases, bead spacing is increased proportionally; when width decreases, bead spacing is reduced, maintaining constant deposition rate throughout the process
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 significantly reduces build times by ensuring a consistent metal deposition rate and proper infilling of complex parts, improving the efficiency and performance of additive manufacturing processes.
Implementation Method 1
a power source configured to provide energy to melt at least the consumable wire electrode by forming an arc between the consumable wire electrode and the build layer
Implementation Method 2
a power source and a laser 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
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AI summary
Embodiments of a system and a method of additive manufacturing are disclosed. A computer control apparatus accesses multiple planned build patterns corresponding to multiple build layers of a three-dimensional (3D) part (22) 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 are 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.