Additive Engine Structure Orientation for Support-Free Internal Ports
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Solution Overview
Problem
Traditional internal combustion engines are heavy, require multiple parts, and have limitations in operating temperature and geometric consistency due to casting and machining processes, leading to inefficiencies and performance issues.
Innovation Solution
The use of additively manufactured structures with specific orientations and materials, such as metal alloys, to create components that are lighter, stronger, and capable of operating at higher temperatures, eliminating the need for support structures in internal passageways and incorporating wear-resistant coatings to enhance performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional casting and machining processes are used to manufacture internal combustion engines, then the engines can be produced with conventional materials, but the engines become heavy, require multiple assembled parts, and have limitations in operating temperature and geometric consistency
Solution Approach 1:
The patent combines multiple engine components into a single monolithic additively manufactured structure, eliminating the need for assembly of multiple cast and machined parts. This integration reduces weight while maintaining or improving strength through the additive manufacturing process and optimized material distribution.
Solution Approach 2:
The patent utilizes metal alloys with specific compositions optimized for additive manufacturing, achieving higher strength-to-weight ratios compared to traditional casting materials. The additive process enables controlled material deposition and potential composite structures with enhanced mechanical properties.
2Manufacturing precision
If traditional casting processes are used, then engines can be manufactured with conventional materials, but geometric consistency and engine timing are compromised
Solution Approach 1:
The patent replaces traditional mechanical casting and machining processes with additive manufacturing technology. This substitution enables direct digital fabrication of complex geometries with high precision and consistency, eliminating tolerance accumulation from multiple machining operations and assembly steps.
3Reliability
If support structures are added during additive manufacturing to ensure structural integrity, then the manufacturing process can proceed, but the internal passageways become blocked and require post-processing
Solution Approach 1:
The patent incorporates support structures during the additive manufacturing process to maintain structural integrity of overhanging features and internal passageways. These support structures are strategically designed and placed, then selectively removed through post-processing operations such as machining or chemical etching, revealing the intended internal geometry.
4Manufacturing precision
If internal surfaces are manufactured with additive manufacturing, then geometric consistency is improved, but the surfaces require additional post-processing to achieve suitable finish for piston contact
Solution Approach 1:
The additive manufacturing process preliminary forms the internal surfaces with high geometric consistency and accuracy. Subsequent post-processing operations such as grinding, polishing, or honing are then applied to achieve the required surface finish for piston contact, combining the advantages of digital fabrication with traditional surface preparation.
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
The solution results in engines with improved strength and durability at elevated temperatures, reducing weight and complexity, while maintaining precise geometric consistency and enabling smoother internal surfaces without the need for machining support structures.
Implementation Method 1
welding a first layer of the additively manufactured structure to the build plate and the first layer of support structures using laser powder bed fusion
Implementation Method 2
applying a wear-resistant coating on the internal body surface of the body bore for subsequent contact by a piston or a piston ring
Implementation Method 3
direct age hardening the additively manufactured structure to increase tensile strength
Data Source
AI summary
A method for manufacturing an additively manufactured structure for an internal combustion engine includes identifying a start point on a build plate for construction of the additively manufactured structure and identifying an orientation of the additively manufactured structure to the build plate such that surface areas of the internal body surface and each internal port surface are at least approximately 20 degrees offset from parallel to the build plate for the additively manufactured structure such that no portion of the surface areas is equivalent to an area of a circle having a radius of 5 mm or larger. The additively manufactured structure includes a body member and at least two gas ports. The body member defines an external body surface and a body bore. The body bore defines an internal body surface. Each gas port defines an external port surface and a port bore. Each port bore defines an internal port surface.