In-Chamber Laser Part Detachment for Additive Manufacturing

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Solution Overview

Problem

Current additive manufacturing processes for aircraft parts require manual removal and mechanical cutting, which are time-consuming, labor-intensive, and result in increased manufacturing costs due to difficulties in achieving accurate and even cuts during part detachment from the build plate.

Innovation Solution

An additive manufacturing apparatus and method featuring a part detachment assembly with laser beam delivery apparatuses that automatically detach parts from the build plate using a cutting laser beam, eliminating the need for manual removal and mechanical cutting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual removal and mechanical cutting are used to detach parts from the build plate, then the detachment process can be performed with simple equipment, but the manufacturing time and labor intensity increase significantly

Engineering Contradiction:
Improvemanufacturing timeVSAvoidequipment complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical cutting system (band saw, lathe, or EDM device) with a laser-based cutting system. The laser assembly delivers a laser beam to automatically cut and detach parts from the build plate, eliminating the need for manual mechanical cutting operations and significantly reducing manufacturing time and labor intensity.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The AM apparatus performs the cutting operation itself using an integrated laser assembly, eliminating the need to manually transport the build plate to external cutting equipment. The build plate remains in the AM apparatus throughout the process, and the laser assembly automatically positions and executes the cutting operation to detach parts.

Inventive Principle:
Principle #25Self-service

2Manufacturing precision

If mechanical cutting devices are used to detach parts from the build plate, then the equipment required is simple and readily available, but the cutting accuracy and evenness deteriorate

Engineering Contradiction:
Improvecutting accuracyVSAvoidequipment complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces mechanical cutting devices with a laser-based cutting system that provides superior cutting accuracy and evenness. The laser beam delivers precise energy to the material, enabling accurate and consistent cuts without the mechanical contact and alignment issues associated with traditional cutting devices.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If manual transport of the build plate is performed from the AM apparatus to the cutting device, then the equipment setup is simple, but the labor intensity and time consumption increase

Engineering Contradiction:
Improvemanufacturing efficiencyVSAvoidoperational simplicity
Core Design Contradiction:
ProductivityVSEase of operation

Solution Approach 1:

The patent merges the cutting function into the AM apparatus by integrating a laser assembly within the build chamber. This combination eliminates the need for separate cutting equipment and manual transport operations, allowing the build plate to remain in place while the laser assembly performs the cutting operation automatically.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The AM apparatus performs the cutting operation itself using an integrated laser assembly, eliminating the need to manually transport the build plate to external cutting equipment. The build plate remains in the AM apparatus throughout the process, and the laser assembly automatically positions and executes the cutting operation to detach parts.

Inventive Principle:
Principle #25Self-service

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 solution reduces manufacturing time and costs by enabling precise and efficient automatic detachment of parts within the additive manufacturing apparatus, improving the accuracy and efficiency of the manufacturing process.

Implementation Method 1

a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts

Methodology Applied
Scientific EffectLaser heating: Laser

Implementation Method 2

one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam... to detach the one or more parts from the build plate

Methodology Applied
Scientific EffectLaser cutting: Laser

Data Source

PatentUS11331754B2Additive manufacturing apparatus and system with a part detachment assembly, and method of using the same
Publication Date: 2022.05.17 THE BOEING CO
  • US11331754B2 patent drawing
  • US11331754B2 patent drawing
  • US11331754B2 patent drawing

AI summary

An AM apparatus for an AM process is provided. The AM apparatus includes a build chamber with a build plate to support one or more parts built with a powder, during a build operation. The AM apparatus further includes a laser assembly operable to deliver a melting laser beam, to melt and fuse the powder used to build the one or more parts. The AM apparatus further includes a part detachment assembly, separate from the laser assembly and operable for a cutting operation. The part detachment assembly includes one or more laser beam delivery apparatuses, each operable to deliver a cutting laser beam, and a part holder apparatus. During the cutting operation, the part holder apparatus holds the one or more parts, and each of the laser beam delivery apparatus(es) delivers the cutting laser beam, to detach the one or more parts from the build plate within the AM apparatus.