Additive Manufacturing of Fluid Pump Cases Using Tilted Orientation

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Solution Overview

Problem

Traditional fuel pump manufacturing methods and designs make it difficult to additively manufacture fuel pumps that are both economical and effective, as they require non-build plate support structures within internal apertures, which can be costly and complex.

Innovation Solution

The method involves additively manufacturing a fluid pump case in a tilted orientation without internal non-build plate support structures, except for coincidental locations intended for post-processing milling, allowing for the elimination of support structures and enabling efficient production of fuel pumps with unique internal features like teardrop-shaped channels and annular grooves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional molding and machining methods are used for fuel pump manufacturing, then manufacturing precision and reliability are maintained, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvemanufacturing costVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines multiple manufacturing operations (molding, machining, support structure installation, and support removal) into a single additive manufacturing process. The support structures are integrated into the build process itself, eliminating the need for separate operations and reducing overall manufacturing complexity while maintaining precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the manufacturing approach from subtractive (molding and machining) to additive manufacturing. This parameter change enables complex internal geometries to be created directly during the build process, reducing the need for post-processing operations and support structure removal, thereby lowering manufacturing costs and complexity.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If non-build plate support structures are used in internal apertures during additive manufacturing, then structural support is provided, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidinternal aperture quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent performs preliminary design of support structures that are coincidental with functional features of the part. By planning support locations in advance to coincide with areas that will be machined anyway, the need for additional support structures is eliminated, simplifying manufacturing while maintaining precision in critical areas.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts the support structure function from separate components and integrates it into the coincidental features that are already part of the final product design. This eliminates the need for separate support structure installation and removal operations, reducing manufacturing complexity while preserving internal aperture quality.

Inventive Principle:

Principle #2Taking out (Extraction)

3Weight of moving object

If additive manufacturing is used for fluid pump case, then weight is reduced and design flexibility improved, but support structure removal and post-processing are required

Engineering Contradiction:

Improvepump case weightVSAvoidpost-processing time

Core Design Contradiction:

Weight of moving objectVSLoss of time

Solution Approach 1:

The patent performs preliminary planning to position support structures in locations that will be removed during standard post-processing operations. By anticipating removal locations in advance and designing supports to be coincidental with machining areas, the patent minimizes additional post-processing time while maintaining the weight and design flexibility benefits of additive manufacturing.

Inventive Principle:

Principle #10Preliminary action

4Device complexity

If tilted orientation is used for additive manufacturing, then support structure in internal apertures is eliminated, but build orientation complexity increases

Engineering Contradiction:

Improvesupport structure complexityVSAvoidbuild orientation setup

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent employs asymmetric tilted orientation (specifically 45 degrees) for additive manufacturing. This asymmetric angle is chosen because it optimally eliminates the need for support structures in internal apertures while remaining a manageable build orientation. The 45-degree tilt creates favorable shadowing effects that allow overhangs to self-support, reducing support structure complexity while the angle is simple enough for manufacturing setup.

Inventive Principle:

Principle #4Asymmetry

Data Source

PatentUS12012971B2Fluid pumps

Publication Date: 2024.06.18 COLLINS ENGINE NOZZLES INC

AI summary

In accordance with at least one aspect of this disclosure, embodiments of fluid pumps, pump cases, valve bodies, and volutes are disclosed herein. Embodiments of methods for manufacturing fluid pumps, pump cases, valve bodies, and volutes are also disclosed herein. Embodiments can include additive manufacturing, for example. Certain embodiments can include additively manufacturing a pump case in a tilted orientation, utilizing only coincidental support structure having a unique shape, and with teardrop shaped volute and/or valve body.