Dynamic Bead Weave Filling for Variable-Width 3D Metal Layers
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Solution Overview
Problem
Conventional additive manufacturing processes are inefficient in filling build layers, particularly for parts with varying layer widths, leading to long build times and inadequate infill techniques.
Innovation Solution
The system dynamically adjusts 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.
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 multiple deposition parameters (weave width, frequency, dwell time, travel speed) in real-time based on the varying width of the build layer, allowing the bead width to adapt continuously to match the layer geometry. This dynamic parameter adjustment enables efficient filling of complex parts with varying widths while maintaining infill quality and reducing build time
Solution Approach 2:
The invention changes physical parameters of the deposition process (weave width, frequency, dwell, travel speed) to optimize the beaded weave pattern for different section widths. By varying these parameters dynamically, the system achieves both high productivity and precise infill placement, resolving the contradiction between fast building and quality infill
2Adaptability or versatility
If the bead width is kept constant during deposition, then the deposition process is simple, but it cannot efficiently fill build layers with varying widths
Solution Approach 1:
The system transitions from static constant bead width to dynamic variable bead width by adjusting deposition parameters in real-time. The computer control apparatus modifies weave width, frequency, and travel speed based on the instantaneous layer width, enabling the system to adapt to varying geometries without requiring complex manual intervention or multiple devices
Solution Approach 2:
By changing the deposition parameters (weave width, frequency, dwell, travel speed) dynamically, the system achieves adaptability to varying layer widths. The computer control apparatus manages this parameter variation, balancing the need for geometric adaptability with acceptable control system complexity
3Productivity
If the travel speed is increased to reduce build time, then productivity improves, but the deposition precision and bead placement accuracy deteriorate
Solution Approach 1:
The system dynamically adjusts travel speed in conjunction with other parameters (weave width, frequency, dwell) to maintain optimal deposition conditions. When traveling faster to improve productivity, the system compensates by adjusting weave width and dwell time to ensure adequate bead placement accuracy, resolving the trade-off between speed and precision
Solution Approach 2:
The invention coordinates changes in multiple parameters (travel speed, weave width, frequency, dwell) to maintain constant deposition rate and bead quality. By changing these parameters together dynamically, the system achieves high travel speeds without sacrificing bead placement accuracy
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 infill performance for complex parts with varying layer widths.
Implementation Method 1
a power source operatively connected to the wire feeder. The power source is 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 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.