Additive Manufacturing Intermediate Part with Dry Gas Circulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in additive manufacturing on a powder bed is the difficulty in effectively removing residual powder from complex parts with internal cavities, which can cause malfunctions and mechanical issues due to its presence in fluid circuits and the complexity of the support system, especially when the support system is fragile or requires costly removal.
Innovation Solution
Incorporating a dry gas circulation circuit within the part and support system during manufacturing, allowing for precise removal of residual powder before separating the part from the build plate, using an inert gas to prevent agglomeration and avoid melting or obstruction, thus simplifying the production process and ensuring efficient powder elimination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a highly compartmentalized support system is used to facilitate residual powder removal, then residual powder can be more easily removed, but the support system becomes fragile and may break during manufacturing
Solution Approach 1:
The support system is divided into multiple compartmentalized regions with internal cavities, creating a segmented structure that facilitates residual powder removal while maintaining overall structural integrity through strategic positioning and connectivity of compartments
2Reliability
If a full support system is used to eliminate failure risk, then structural reliability is improved, but support system removal becomes complex and costly
Solution Approach 1:
A dry gas circulation circuit is integrated into the support system during manufacturing to preliminarily remove residual powder before the support system needs to be removed, eliminating the need for complex post-manufacturing powder removal operations
3Productivity
If residual powder is not removed, then manufacturing complexity is reduced, but malfunctions occur due to powder blocking fluid circuits
Solution Approach 1:
The support system is designed with integrated dry gas circulation circuits that enable it to automatically remove residual powder from internal cavities and fluid circuits during the manufacturing process itself, making the support system self-serving for powder removal
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 effective and efficient removal of residual powder from internal cavities, preventing malfunctions and mechanical issues, while reducing manufacturing costs and complexity by allowing for one-piece production of complex parts with internal cavities.
Implementation Method 1
the dry gas circulation circuit being configured to allow the dry gas to circulate between the part support system and an orifice opening onto an external surface of the part via the internal cavity of the part and the internal cavity of the support system
Implementation Method 2
A dry gas is defined as an inert gas with a relative humidity of less than or equal to 1.0%, preferably less than or equal to 0.1% at 23°C. Indeed, humidity could cause the residual powder to clump together, making its removal more difficult, or even impossible.
Implementation Method 3
For instance, in applications such as combustion chamber or rocket engine gas generator injection nozzles, residual powder can cause malfunctions in the injection nozzle by partially or completely blocking the fluid circuits, potentially leading to local melting of the material or even significant degradation that can result in flames, for example, when the residual powder comes into contact with liquid oxygen.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an intermediate part (10) obtained by a powder bed additive manufacturing process, comprising a part (12) having at least one internal cavity and a support system for the part (12) having at least one internal cavity, the intermediate part (10) comprising at least one dry gas circulation circuit, the dry gas circulation circuit being configured to allow the dry gas to circulate between the support system of the part and an orifice opening onto an external surface of the part (12) via the internal cavity of the part (12) and the internal cavity of the support system. The invention also relates to an assembly comprising the intermediate part and its manufacturing process.