Hybrid Additive Manufacturing via Segmented Build Data
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Solution Overview
Problem
The existing methods for additive manufacturing of hybrid objects, which consist of both additively and non-additively manufactured parts, are inefficient and lack process integration, requiring separate manufacturing steps and different manufacturing processes for each part.
Innovation Solution
A method that subdivides the data record for additive manufacturing into sub-data records for each object part, allowing each part to be formed in separate additive construction processes with different construction parameters, such as materials and energy beam settings, enabling the production of objects with varying properties within the same system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hybrid objects are manufactured using separate non-additive and additive manufacturing steps, then different object properties can be achieved in different parts, but the manufacturing process becomes more complex and less efficient
Solution Approach 1:
The data record is subdivided into at least two sub-data records, where a first sub-data record describes a first sub-object forming a first object part and at least one further sub-data record describes a further sub-object forming a further object part. This segmentation allows different additive construction processes with different parameters to be applied to different parts of the same object, achieving varied object properties while maintaining process integration.
Solution Approach 2:
The additive construction apparatus is configured to perform multiple additive construction processes for forming different sub-objects within the same system. By subdividing the data record and applying different construction parameters (materials, energy beam settings) to different sub-objects, the system achieves multi-functionality, allowing production of hybrid-like objects with different properties using a single integrated additive manufacturing process.
2Adaptability or versatility
If hybrid objects are manufactured using separate non-additive and additive manufacturing steps, then different object properties can be achieved in different parts, but productivity decreases due to multiple manufacturing steps
Solution Approach 1:
The patent merges the previously separate non-additive and additive manufacturing steps into a single integrated additive manufacturing process. By subdividing the data record into sub-data records and applying different additive construction processes with varying parameters (materials, energy beam settings) to different sub-objects within the same apparatus, the system combines multiple manufacturing capabilities into one unified process, thereby improving productivity while maintaining the ability to produce objects with different properties.
3Adaptability or versatility
If separate manufacturing processes are used for different object parts, then each part can be optimized for its specific requirements, but process integration is reduced
Solution Approach 1:
The data record is subdivided into at least two sub-data records, where a first sub-data record describes a first sub-object forming a first object part and at least one further sub-data record describes a further sub-object forming a further object part. This segmentation enables different additive construction processes with optimized construction parameters (materials, energy beam settings) to be applied to different parts while maintaining integration within a single additive manufacturing system.
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
This approach improves the efficiency and integration of the manufacturing process by allowing the production of objects with different properties using the same system, enabling the complete additive manufacturing of hybrid objects that were previously produced with mixed methods.
Implementation Method 1
The additive manufacture of corresponding objects proceeds by successive, selective layer-by-layer solidification of construction material layers by means of an energy beam. The energy beam may be a laser beam.
Implementation Method 2
The method may accordingly be a selective laser melting method (SLM method for short) or a selective laser sintering method (SLS method for short).
Implementation Method 3
The method may accordingly be a selective laser melting method (SLM method for short) or a selective laser sintering method (SLS method for short).
Data Source
AI summary
A method for additive manufacturing of an object, in particular a hybrid object, based on a data record describing an object to be additively manufactured, includes providing a data record describing the object to be additively manufactured, subdividing the data record into at least two sub-data records, wherein a first sub-data record describes a first sub-object forming a first object part of the object to be additively manufactured, and at least one other sub-data record describes another sub-object forming another object part of the object to be additively manufactured, forming the first sub-object based on the first sub-data record in a first additive construction process, and forming the at least one other sub-object based on the at least one other sub-data record in at least one separate other additive construction process, wherein the at least one other sub-object is formed at least partially, especially completely, on the first sub-object.