Additive Manufacturing Fluid Pump Case Tilted Build 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 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 Y-shaped support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fuel pump manufacturing methods are used, then support structures are required in internal apertures, but this increases manufacturing complexity and cost
Solution Approach 1:
The patent removes the need for support structures within internal apertures by reorienting the build direction. The fluid pump case is manufactured with the build direction aligned perpendicular to the major planar surface, allowing internal apertures to be formed without requiring support structures that would complicate post-processing and increase manufacturing complexity.
Solution Approach 2:
The patent changes the build orientation dimension to resolve the support structure issue. By positioning the build direction perpendicular to the major planar surface rather than parallel to it, the internal apertures can be manufactured without intersecting support structures, effectively using a dimensional change to eliminate the problem.
2Productivity
If non-build plate support structures are used in internal apertures, then the pump can be manufactured, but additional support removal processing is required
Solution Approach 1:
The patent performs preliminary action by correctly orienting the build direction from the start of the manufacturing process. By setting the build direction perpendicular to the major planar surface before manufacturing begins, the design ensures that internal apertures do not require support structures, eliminating the need for subsequent support removal operations and saving processing time.
3Device complexity
If the build direction is not aligned with the major planar surface, then support structures are needed, but aligning them reduces manufacturing complexity
Solution Approach 1:
The patent establishes a universal build orientation rule where the build direction is consistently aligned perpendicular to the major planar surface of the fluid pump case. This multi-functional orientation simultaneously simplifies the manufacturing process, eliminates support structure requirements in internal apertures, and provides a consistent design guideline for various pump configurations.
Data Source
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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.