Laminated Molding Closure for Support-Free Internal Spaces
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Solution Overview
Problem
The existing methods for manufacturing additively-manufactured objects with internal spaces face challenges in removing support materials, especially in closed or narrow spaces, requiring time and effort, and using fluid support materials is not efficient due to handling difficulties.
Innovation Solution
A method involving the formation of an additively-manufactured object with an opening wider than the weld bead width, followed by a closing step where a closing wall portion, also wider than the weld bead, is formed using the weld bead to seal the opening, allowing for easy creation of internal spaces without the need for support material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support material is used to build internal spaces, then built objects with internal spaces can be manufactured, but support material removal requires time and effort and cannot reach closed or narrow spaces
Solution Approach 1:
The opening is formed with a width dimension larger than the bead width of the weld bead during the additively-manufacturing step, preliminarily preparing access for the closing operation. This preliminary sizing enables subsequent easy closure without requiring support material removal, thus resolving the time-consuming removal issue while maintaining internal space manufacturability
Solution Approach 2:
The support material is completely eliminated from the manufacturing process. Instead of using support material and then removing it, the invention uses a closing wall portion formed by weld beads to close the opening, thereby extracting the support material function entirely and eliminating the associated removal time and complexity
2Ease of operation
If fluid support material is used for narrow spaces, then support material can be removed, but handling becomes difficult and removal work still takes time and effort
Solution Approach 1:
The invention extracts the support material concept entirely from the process. Instead of using fluid or granular support materials that require handling and removal operations, the method uses a closing wall portion formed by depositing weld beads to close the opening, eliminating all handling complexity and removal operations
Solution Approach 2:
The opening structure serves as a temporary feature that is intentionally designed to be closed. The opening with width dimension larger than bead width is created temporarily during manufacturing, then closed by the closing wall portion, making the opening a disposable temporary feature rather than a permanent structural element
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 enables the easy manufacturing of additively-manufactured objects with internal spaces, preventing molten metal penetration and ensuring high bonding strength by forming a wide closing wall portion from the weld bead, thus overcoming the inefficiencies of traditional support material removal processes.
Implementation Method 1
building a layered body by depositing a weld bead obtained by melting and solidifying a filler metal
Implementation Method 2
forming a closing wall portion connecting an edge portion of the opening with the weld bead for closing
Data Source
AI summary
A method for manufacturing an additively-manufactured object, includes: an additively-manufacturing step of building a layered body by depositing a weld bead obtained by melting and solidifying a filler metal, the layered body having an opening along a forming direction of the weld bead and an internal space surrounded by the weld bead; and a closing step of forming a closing wall portion connecting an edge portion of the opening with the weld bead for closing. In the additively-manufacturing step, the opening is formed with a width dimension larger than a bead width of the weld bead, and in the closing step, the closing wall portion having a width dimension larger than the bead width is formed by the weld bead to close the opening.