Hybrid Cast Housing With Additive Features for Complex Geometry

Solution Overview

Problem

Existing casting technologies face challenges in efficiently producing components with intricate features due to the high cost and long lead time required for preparing complex molds, leading to increased assembly times, costs, and process complexities.

Innovation Solution

A hybrid casting-additive manufacturing process that combines a cast body formed using a mold with features deposited using a solid state additive manufacturing process, allowing for the creation of components with complex internal and external features without reaching the melting temperature of the material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional casting with complex molds is used to create components with intricate features, then manufacturing precision can be achieved, but the cost and lead time for mold preparation increase significantly

Engineering Contradiction:

Improvecomponent geometry accuracyVSAvoidmold preparation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The manufacturing process is segmented into two distinct stages: (1) casting the base component structure using traditional mold methods, and (2) adding intricate features through solid state additive manufacturing. This segmentation allows the mold to be simple while still achieving complex final geometries, resolving the contradiction between manufacturing precision and mold preparation time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent merges two manufacturing methods - traditional casting and solid state additive manufacturing - into a hybrid process. The cast body serves as the substrate, and additive manufactured features are deposited directly onto it, combining the advantages of both methods to achieve complex geometries without complex molds.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If traditional casting with complex molds is used to create components with intricate features, then manufacturing precision can be achieved, but the cost of mold preparation increases prohibitively

Engineering Contradiction:

Improvecomponent geometry accuracyVSAvoidmold preparation cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The manufacturing process is segmented into two distinct stages: (1) casting the base component structure using traditional mold methods, and (2) adding intricate features through solid state additive manufacturing. This segmentation allows the mold to be simple while still achieving complex final geometries, resolving the contradiction between manufacturing precision and mold preparation time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent merges two manufacturing methods - traditional casting and solid state additive manufacturing - into a hybrid process. The cast body serves as the substrate, and additive manufactured features are deposited directly onto it, combining the advantages of both methods to achieve complex geometries without complex molds.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If solid state additive manufacturing is used to deposit features on a cast body, then adaptability for design changes is improved, but the process complexity increases

Engineering Contradiction:

Improvedesign change capabilityVSAvoidhybrid process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The solid state additive manufacturing system serves multiple functions: it can add various intricate features, modify existing geometries, create attachment points, and accommodate design changes. This multi-functionality justifies the added process complexity by providing universal adaptability for different design requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cast body is prepared in advance with a simplified geometry that serves as a stable substrate. This preliminary action allows the additive manufacturing process to focus solely on adding features, simplifying the overall control of the hybrid process while maintaining design adaptability.

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

This approach improves the throughput and efficiency of fabricating components by reducing assembly times, costs, and process complexities, while providing unprecedented control over material properties and enabling the production of components with complex features that would be difficult to achieve with traditional casting methods.

Implementation Method 1

at least one feature deposited on the cast body using a solid state additive manufacturing process in which a melting temperature of a material of the at least one feature is not reached

Methodology Applied

Scientific EffectSolid state additive manufacturing: 3D Printing

Data Source

PatentUS20250187073A1Housing and method of preparing same using a hybrid casting-additive manufacturing process

Publication Date: 2025.06.12 LOCKHEED MARTIN CORP

AI summary

The present disclosure is directed, in certain embodiments, a component of a mechanical apparatus. The component includes a cast body with an initial structure formed by a mold and at least one feature deposited on the cast body using a solid state additive manufacturing process, such that in combination the initial structure and the at least one feature form a complete structure of the component.