Fluid Flushing of Internal Channels for Additive Manufacturing FOD

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Solution Overview

Problem

Additive manufacturing introduces challenges in managing Foreign Object Debris (FOD) due to complex internal structures, where debris can obstruct fluid flow and cause efficiency issues or damage, and existing methods to manage FOD in subtractive processes are inefficient or increase production costs.

Innovation Solution

A fluid flushing system that connects a part with internal channels to a pump, pressurizes the part with fluid, breaches internal channels to form openings, and uses a fluid current to flush away debris, incorporating features like adapters, manifolds, and rotating fluid distribution devices to ensure effective debris removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If additive manufacturing is used to create parts with complex internal structures, then manufacturing capability and design flexibility are improved, but the risk of FOD obstruction in internal channels increases

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidFOD obstruction risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary flushing operations before FOD can obstruct the internal channels. By establishing fluid flow through the channels ahead of time, debris is removed proactively rather than reactively after obstruction occurs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses hydraulic flushing systems with pumps, fluid sources, and controlled fluid flow to transport FOD through the internal channels and out of the part. The fluid current generated by the pump system carries debris away from critical passages.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Object-affected harmful factors

If traditional FOD management methods from subtractive processes are applied to additive manufacturing, then some debris control is achieved, but production costs increase and efficiency decreases

Engineering Contradiction:

ImproveFOD controlVSAvoidproduction efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The flushing system is integrated with the additive manufacturing process itself, combining the manufacturing operation with the FOD removal operation. The fluid flushing system uses the part's own internal channels as the flushing pathway, eliminating the need for separate, complex FOD management equipment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The part's internal channels serve dual purposes: their intended function and as flushing pathways for FOD removal. The system uses the part's own structure to facilitate its own cleaning, reducing the need for external intervention and additional equipment.

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If internal channels are breached to remove FOD, then debris can be flushed away, but the structural integrity of the part may be compromised

Engineering Contradiction:

Improvedebris removalVSAvoidstructural integrity

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

Breaching operations are performed only at specific, predetermined locations where the part structure can tolerate the opening without compromising overall integrity. The flushing system is designed to work with the local structural characteristics of the part.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The fluid acts as an intermediary medium to transport FOD from the internal channels to the exterior through the breached opening. The opening serves as a controlled interface that allows debris removal while maintaining the rest of the part structure intact.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system effectively prevents FOD by flushing it away, maintaining fluid flow and reducing the risk of obstruction, while also providing cooling and optimizing production efficiency by integrating with machining operations.

Implementation Method 1

operating the pump to pressurize the part with a fluid

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Implementation Method 2

pumping the fluid through the internal channel and the opening to produce a fluid current

Methodology Applied

Scientific EffectFluid flow: Fluid Spray

Implementation Method 3

pumping the fluid through the internal channel and the opening, further provides cooling to the machining device

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS20260034568A1Fluid Flushing Systems for Foreign Object Debris Amelioration, and Methods and Devices Related Thereto

Publication Date: 2026.02.05 RELATIVITY SPACE INC

AI summary

Methods, apparatus, and devices for fluid flushing systems to remove foreign object debris (FOD) are provided. These methods and devices are designed to flush and transport FOD away from machined parts. Foreign object debris refers to any unintended material such as tiny particles, chips that enters a part during a manufacturing process. FOD can have significant effects, compromising the quality and functionality of manufactured items. This can lead to costly consequences such as rework, scrapped parts, and production delays. FOD prevention is essential for improving safety, reliability, and efficiency.