Hybrid Raw Material Build-Up for Low-Waste Component Manufacturing

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Solution Overview

Problem

Existing methods for manufacturing components from forgings result in significant material waste and are limited in complexity, while additive manufacturing for large components is costly and inefficient for scaling from low to high volume production, and there is a risk of defects leading to component discard.

Innovation Solution

A hybrid manufacturing method combining forging and additive manufacturing to create a hybrid raw material block, where a first portion is forged and a second portion is additive manufactured, followed by machining to form the final component, minimizing waste and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional forging is used to manufacture components, then production efficiency is improved, but material waste increases and complexity is limited

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmaterial waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The component is divided into two portions: a first portion manufactured by forging and a second portion manufactured by additive manufacturing. This segmentation allows each manufacturing method to be applied to the most suitable portion, optimizing both production efficiency and material utilization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different manufacturing methods are applied to different portions of the component based on local requirements. The first portion is forged for efficiency, while the second portion is additively manufactured to achieve complex geometries with minimal material waste.

Inventive Principle:

Principle #3Local quality

2Device complexity

If additive manufacturing is used for large components, then complexity is improved, but production cost increases and scalability deteriorates

Engineering Contradiction:

Improvecomponent complexityVSAvoidproduction scalability

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The component is segmented into a first portion suitable for forging and a second portion requiring additive manufacturing. This allows the majority of the component to be produced efficiently while only the complex portion uses additive manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Additive manufacturing is applied partially to only the second portion of the component rather than the entire component. This reduces production cost and improves scalability while still achieving the required complexity in the critical area.

Inventive Principle:

Principle #16Partial or excessive action

3Loss of substance

If additive manufacturing is used for protruding features, then material waste is reduced, but production cost increases

Engineering Contradiction:

Improvematerial wasteVSAvoidproduction cost

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

Additive manufacturing is applied locally to the second portion containing protruding features where it provides material efficiency, while the first portion is forged for cost-effectiveness.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Additive manufacturing is used partially only for the protruding features and second portion rather than the entire component, balancing material efficiency with production cost.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentEP4631648A1Raw material build-up using additive manufacturing

Publication Date: 2025.10.15 PRATT & WHITNEY CANADA CORP

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AI summary

A method for fabricating a component (10) from a hybrid raw material, comprising the steps of: forging a first portion of a raw material for the component; additive manufacturing a second portion (24) of a raw material to the first portion to produce a hybrid raw material; and machining the hybrid raw material to produce the component (10). A repair method is also disclosed.