Intersecting Rib Deposition Paths to Limit Heat Buildup

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing additive manufacturing techniques for producing intersecting ribs face challenges such as material wastage and overheating at the intersection zones, which can lead to deterioration of mechanical properties, especially when using titanium materials.

Innovation Solution

The method involves depositing layers of material using focused energy to create intersecting ribs by forming beads of material that connect at the intersection points, with specific deposition trajectories that minimize overheating, such as using rectilinear, L-shape, or continuous beads to build up the ribs, allowing for controlled material deposition and reduced waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If additive manufacturing is used to produce intersecting ribs by superposing layers of material, then material wastage is reduced, but overheating occurs at intersection zones leading to deterioration of mechanical properties

Engineering Contradiction:

Improvematerial wastageVSAvoidmechanical properties

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The rib structure is segmented into multiple deposition zones: first ribs are deposited completely, then second ribs are deposited in segments that avoid the intersection zones with first ribs. This segmentation prevents simultaneous heating of intersecting ribs, eliminating overheating while maintaining additive manufacturing's material efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first ribs are deposited in advance before depositing the second ribs. This preliminary action establishes a foundation structure that allows subsequent ribs to be deposited without causing overheating at intersections, as the deposition sequence is carefully controlled to avoid concurrent heating

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If conventional machining is used to remove material between ribs, then intersecting ribs can be produced, but great losses of material occur in the form of swarf

Engineering Contradiction:

Improveintersecting rib productionVSAvoidmaterial loss

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The conventional mechanical machining process is replaced with an additive manufacturing process using focused energy deposition. Instead of removing material with milling cutters, material is added layer by layer to form ribs directly, eliminating swarf generation while achieving precise intersecting rib geometries

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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 reduces material wastage and maintains the mechanical properties of the material by strategically depositing beads to manage heat distribution, enabling efficient production of ribbed panels with intersecting ribs without significant overheating.

Implementation Method 1

a part obtained by additive manufacturing by stacking layers of material obtained by melting a material using a focused energy source

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

a focused energy source, such as a laser beam or an electron beam for example

Methodology Applied

Scientific EffectLaser Beam: Laser

Implementation Method 3

In a directed energy deposition (DED) technique using focused energy the material in the form of wires is deposited simultaneously with the input of energy

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS20230364680A1Additive manufacturing method by deposition of material under focused energy enabling production of intersecting ribs and ribbed part obtained using said method

Publication Date: 2023.11.16 AIRBUS OPERATIONS (SAS)

AI summary

A method for additive manufacturing at least one intersection of first and second ribs by stacking layers of material, at least one layer of material of a first section of the first rib being obtained by depositing at least one bead of material that extends on respective opposite sides of the intersection. Wherein in that at least one layer of material of a second section of the second rib comprises a first part obtained by depositing at least one bead of material at a distance from the first section that extends in the direction of the second section and a second part obtained by depositing at least one bead of material adjacent to the first section that extends in the first direction. Also a method of manufacturing a ribbed panel and a ribbed panel.