Embedded Cooling Channels for Additive Manufacturing Temperature Control
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in effectively controlling temperature dynamics during processes like selective laser sintering or electron beam melting, leading to residual stresses in work pieces, which can be alleviated through post-processing but may result in permanent deformation, and conventional build plate temperature control methods are not always sufficient.
Innovation Solution
Incorporating a temperature control channel within the build, formed layer by layer, and flowing fluid through it to provide real-time temperature control, with the option to add multiple channels at successive levels and connect them via thermally conductive connectors, allowing for precise temperature management during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If post-process heat treating is used to eliminate residual stresses, then residual stresses are reduced, but permanent deformation of the work piece occurs
Solution Approach 1:
The patent applies preliminary action by implementing temperature control channels within the build plate that actively manage temperature dynamics during the additive manufacturing process itself. This prevents residual stress formation at the source through real-time thermal management, eliminating the need for post-process heat treating and avoiding the deformation that would result from such post-processing.
2Temperature
If conventional build plate temperature control is used, then some temperature management is achieved, but precise localized temperature control during manufacturing is insufficient
Solution Approach 1:
The patent applies segmentation by dividing the temperature control function into multiple independent temperature control channels embedded within the build plate. Each channel can be independently controlled to provide localized temperature management at different positions and depths, enabling precise thermal control during additive manufacturing that addresses specific hot spots or stress regions rather than applying uniform temperature control.
Solution Approach 2:
The patent implements local quality by enabling different regions of the build plate to have different temperature characteristics through the distributed temperature control channels. Each channel can be independently regulated to provide tailored temperature conditions for specific areas of the work piece, allowing precise control of temperature gradients and localized thermal management during the manufacturing process.
3Temperature
If temperature control channels are added to provide real-time temperature control, then temperature management precision is improved, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating the temperature control channels directly into the build plate structure itself, combining the thermal management function with the support structure. This integration reduces device complexity compared to having separate external temperature control systems, as the channels are embedded within the existing build plate geometry and share the same physical space and material structure.
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 method enables precise temperature control throughout the additive manufacturing process, reducing residual stresses without causing permanent deformation, by allowing for continuous and localized temperature adjustments, thereby improving the quality and consistency of the final product.
Implementation Method 1
flowing fluid through the temperature control channel while continuing to additively manufacture the build to provide temperature control for the build in progress
Implementation Method 2
forming, through additive manufacturing, thermally conductive connectors connecting between the temperature control channel and a portion of the build spaced apart from the temperature control channel for heat transfer between the temperature control channel and the portion of the build
Data Source
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AI summary
A method includes beginning an additively manufactured build (104, 204, 304) by depositing initial layers of the build on a build plate, and additively manufacturing a temperature control channel as part of the build in progress. The method also includes flowing fluid through the temperature control channel while continuing to additively manufacture the build to provide temperature control for the build in progress. The method also includes completing additive manufacture of the build. The method can include removing the temperature control channel from the build after completion of the build.