Granular Support Bed for CT Scanning Embedded Components

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Solution Overview

Problem

Existing CT scanning methods face challenges in providing robust and efficient support for components during scanning, as traditional fixtures offer limited rigidity or require lengthy manufacturing times, making it difficult to maintain components in desired orientations and distinguish them from the scanning environment.

Innovation Solution

A method using a support bed with granular material of lower density than the component, embedded within a container, which supports the component in various orientations, utilizing a barrier to prevent contact and allowing easy repositioning, and optionally combined with a rigid support element or flexible walls to maintain scanning position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If foam fixtures are used to support the component, then the component can be easily distinguished from the fixture in the 3D model due to density difference, but the fixture offers low strength and has only limited ability to rigidly retain the component

Engineering Contradiction:

Improveimage differentiationVSAvoidfixture strength

Core Design Contradiction:

Measurement precisionVSStrength

Solution Approach 1:

The support system is divided into multiple granular particles that collectively provide support. Each particle is individually low-density for good image differentiation, but collectively they provide sufficient support strength when the component is embedded in the granular material.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The density parameter of the support material is changed from solid (high density) to granular (low density). This allows the support material to have lower density than the component for better image differentiation, while still providing adequate strength through the collective effect of multiple particles.

Inventive Principle:

Principle #35Parameter changes

2Strength

If robust fixtures are made using 3D printing or moulding to increase strength, then the fixture can rigidly retain the component, but the manufacturing time is long which is undesirable

Engineering Contradiction:

Improvefixture strengthVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The granular material support bed acts as a disposable or easily resettable support system. Instead of manufacturing durable fixtures that take time to produce, the system uses readily available granular material that can be quickly prepared and reused, significantly reducing manufacturing time.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The granular material automatically conforms to the component shape and provides support through its own weight and particle interlocking. The system is self-configuring and requires no complex manufacturing processes, tooling, or assembly operations.

Inventive Principle:

Principle #25Self-service

3Reliability

If a barrier is disposed between the component and granular material to separate them, then the component can be protected from contact with granular material, but the barrier adds an additional material layer that may affect scanning

Engineering Contradiction:

Improvecomponent protectionVSAvoidsupport system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A thin flexible barrier film is used to separate the component from the granular material. The film is thin enough to minimize interference with X-ray scanning while providing sufficient protection. The flexibility allows it to conform to the component shape and the granular material movements.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Enables rapid reconfiguration of scanning orientations, clear image differentiation, and reduced material waste by using a reusable support system that effectively distinguishes components from the scanning environment.

Implementation Method 1

the granular material having a second density lower than the first density

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 2

scanning the component in the scanning orientation by X-ray or gamma ray scanning to produce an image of the component

Methodology Applied

Scientific EffectX-ray attenuation: X-Ray

Data Source

PatentUS12510495B2Method of scanning a component embedded in a granular material using computed tomography

Publication Date: 2025.12.30 ROLLS ROYCE PLC

AI summary

The present disclosure provides a method of scanning a component by computed tomography, the method comprising: providing the component having a first density; supporting the component in a scanning orientation using a support bed, the support bed comprising a granular material disposed in a container, the granular material having a second density lower than the first density; wherein supporting the component comprises at least partially embedding the component in the granular material. The method further comprises scanning the component in the scanning orientation by X-ray or gamma ray scanning to produce an image of the component.