Inclined Surface Additive Forming Without Support Structures
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Solution Overview
Problem
Additive manufacturing techniques, such as laser melting deposition, face challenges in forming parts with inclined surfaces without support structures, leading to limitations in the angle of inclination that can be achieved and increased material waste and processing time due to the need for auxiliary supports.
Innovation Solution
A method involving layer separating and slicing, scanning path planning with distinct energy densities for different paths, and adjusting laser power and scanning rate to form parts with inclined surfaces, allowing for the formation of acute angles without additional supports by creating a larger molten pool at suspended areas to compensate for gravity-induced collapse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If auxiliary support structures are added to form inclined surfaces in additive manufacturing, then the angle of inclination can be increased beyond 30°, but material waste and processing time increase significantly
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting laser power and scanning speed based on the local geometry of the inclined surface. Different regions (suspended areas vs. supported areas) are processed with different parameter sets, allowing the molten pool to be better controlled and compensated for gravity-induced collapse without requiring additional support structures.
Solution Approach 2:
The patent implements dynamics by making the processing parameters dynamic rather than static. The laser power and scanning speed are adjusted in real-time according to the position and orientation of each deposited layer, enabling adaptive control of the molten pool behavior to achieve larger inclination angles without supports.
2Shape
If auxiliary support structures are added to form inclined surfaces, then the angle of inclination can be increased, but processing time increases due to adding and removing supports
Solution Approach 1:
By changing processing parameters (laser power, scanning speed) according to the specific geometry of each layer, the method achieves stable deposition on inclined surfaces without supports, eliminating the time-consuming steps of adding and removing auxiliary support structures.
Solution Approach 2:
The method enables the inclined surface to support itself through optimized processing parameters that control molten pool behavior, eliminating the need for external support structures and their subsequent removal, thus reducing processing time.
3Manufacturing precision
If energy density is increased in suspended areas, then deposition accuracy improves by compensating for gravity collapse, but energy consumption increases
Solution Approach 1:
The patent applies local quality by implementing different energy densities in different regions of the inclined surface. Suspended areas receive higher energy density to compensate for gravity-induced collapse, while supported areas use lower energy density, optimizing both deposition accuracy and energy efficiency locally.
Solution Approach 2:
The method changes energy density parameters spatially and temporally, adjusting laser power and scanning speed based on the local geometry and support conditions, thereby achieving precise deposition control with optimized energy consumption.
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 method enables the formation of parts with inclined surfaces at angles greater than 30° without auxiliary supports, reducing material waste and processing time, while improving the accuracy and quality of the formed parts by ensuring sufficient deposition and metallurgical bonding.
Implementation Method 1
laser melting deposition technique is a kind of additive manufacturing technique with advanced direct energy deposition
Implementation Method 2
the powder at this position will be subjected to the relatively large energy density and be melted and deposited to form a larger and thicker molten pool, which compensates the lack of deposition amount caused by the collapse of the molten pool at the position of the inclined structure due to the gravity acting on part of the suspended area
Data Source
AI summary
A method for forming a forming part with an inclined surface and a forming part with an inclined surface wherein the forming method comprises: obtaining a model of the part to be formed; performing layer separating and slicing process to form a plurality of forming layers; a performing scanning path planning on each forming layer, wherein a suspended area and a non-suspended area are provided in a plurality of forming layers forming the inclined surface, frame scanning path comprises a first path and a second path, the first path corresponds to the non-suspended area and the second path corresponds to the suspended area; based on the size of the angle of inclination, setting process parameters for the first path and the second path, and printing layer by layer based on the set process parameters; wherein an energy density in the process parameters of the first path is smaller than an energy density in the process parameters of the second path. The forming method can ensure the angle of inclination of the inclined surface to form effectively.