Hybrid Additive Structures Using Multi-Process Build and Mandrel Support

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Solution Overview

Problem

Existing additive manufacturing processes face limitations in producing complex geometries and large components efficiently, with powder bed fusion being limited to smaller components and direct-energy deposition being costly for detailed features, and thermal stresses causing deformation during manufacturing.

Innovation Solution

Combining multiple additive manufacturing processes to form hybrid structures, using a base plate for rigidity and mandrel assistance, and incorporating specialized structures like struts to manage thermal disparities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If powder bed fusion is used for additive manufacturing, then manufacturing precision and design freedom are improved, but component size is limited to smaller dimensions

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidcomponent size

Core Design Contradiction:

Manufacturing precisionVSVolume of moving object

Solution Approach 1:

The patent divides a large component into multiple sub-components that can be manufactured separately using powder bed fusion and then assembled together. This allows each sub-component to be produced with high precision while the overall structure achieves large scale, resolving the contradiction between manufacturing precision and component size.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If direct-energy deposition is used for large components, then component size is improved, but manufacturing cost increases for detailed features

Engineering Contradiction:

Improvecomponent sizeVSAvoidmanufacturing cost

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent applies different manufacturing processes to different regions of the component based on local requirements. Powder bed fusion is used for regions requiring high precision and complex geometry, while direct-energy deposition or conventional manufacturing is used for larger, less detailed regions, optimizing cost-effectiveness across the entire component.

Inventive Principle:

Principle #3Local quality

3Volume of moving object

If multiple sub-components are assembled together, then large structures can be formed, but joint integrity and assembly complexity increase

Engineering Contradiction:

Improvestructure sizeVSAvoidassembly complexity

Core Design Contradiction:

Volume of moving objectVSDevice complexity

Solution Approach 1:

The patent combines multiple sub-components into an integrated assembly with optimized joint design. By carefully designing the interfaces and connection features between sub-components during the modeling stage, the assembly process is simplified while maintaining joint integrity, reducing the overall complexity of assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If additive manufacturing is used for hybrid structures, then design freedom is improved, but thermal stresses cause deformation

Engineering Contradiction:

Improvedesign freedomVSAvoiddeformation control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent incorporates preliminary design features such as integrated cooling channels, thermal barriers, and stress relief geometries directly into the 3D printed models before manufacturing. These pre-planned thermal management features prevent thermal stress accumulation and deformation during the additive manufacturing process, maintaining precision while enabling hybrid structure design freedom.

Inventive Principle:

Principle #10Preliminary action

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

Hybrid structures achieve greater design freedom, improved joint integrity, and reduced deformation, enabling efficient production of complex components with enhanced mechanical properties.

Implementation Method 1

a first component (110) is formed via additive manufacturing

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

wherein the first material is a low thermal conductivity material

Methodology Applied

Scientific EffectThermal conductivity: Conduction (thermal)

Data Source

PatentEP4703068A1Additive manufacturing of hybrid structures

Publication Date: 2026.03.04 RELATIVITY SPACE INC

Figure 1
Figure 2A~2B
Figure 2C~2D

AI summary

The disclosure presents a combination of additive manufacturing processes that could be used to produce different portions or features of a hybrid structure, such that a first additive manufacturing process could be used to form a complex seed part or first section of the hybrid component, and a different additive manufacturing component could be used to form a second section of the hybrid component. When two components are manufactures, a mandrel could be assembled into the first component to provide rigidity and resistance to deformation of the first component, even during and after formation of the second component on the interface surface of the first component using a second additive manufacturing process. Finally, struts could be formed directly on a base plate and before formation of the component so that the base plate temperature could increase to be in equilibrium with the temperature of the newly deposited material.