In-Situ Laser Part Detachment for Additive Manufacturing Build Plates

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Solution Overview

Problem

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

Innovation Solution

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

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

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 increases and labor intensity increases

Engineering Contradiction:

Improvedetachment process simplicityVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSProductivity

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 cut and detach the part from the build plate, eliminating the need for manual mechanical cutting operations while significantly reducing detachment time and automating the process within the additive manufacturing apparatus.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges the detachment function into the additive manufacturing apparatus by integrating a laser assembly and part removal assembly within the same build chamber. This allows the detachment operation to be performed in-situ without removing the build plate from the apparatus, combining multiple operations (building and detaching) into a single integrated system.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If manual removal and mechanical cutting are used to detach parts from the build plate, then the equipment complexity remains low, but labor intensity increases

Engineering Contradiction:

Improveequipment complexityVSAvoidlabor intensity

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent replaces manual mechanical cutting operations with an automated laser cutting system. The laser assembly is controlled to automatically cut and detach the part from the build plate, eliminating the need for operators to manually handle and transport the build plate to external cutting devices, thereby reducing labor intensity while maintaining relatively simple equipment architecture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If mechanical cutting devices are used to detach parts from the build plate, then the detachment can be performed outside the additive manufacturing apparatus, but the cutting accuracy decreases

Engineering Contradiction:

Improvedetachment accessibilityVSAvoidcut accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent uses a laser-based cutting system instead of mechanical cutting devices. The laser beam can precisely cut through the fused material between the part and build plate, achieving high cutting accuracy that is difficult to obtain with mechanical cutting tools. The laser system is positioned within the build chamber to deliver the laser beam directly to the interface between the part and build plate.

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 solution reduces manufacturing time and costs by enabling precise and efficient detachment of parts within the apparatus, improving the accuracy of cuts and streamlining 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 heating: Laser

Data Source

PatentEP3656498B1Additive manufacturing apparatus with a part detachment assembly, and method of using the same

Publication Date: 2023.04.26 THE BOEING CO

Figure 1A
Figure 1B
Figure 2A

AI summary

An AM apparatus (10) for an AM process (12) is provided. The AM apparatus (10) includes a build chamber (20) with a build plate (28) to support one or more parts (22) built with a powder (24), during a build operation (26). The AM apparatus (10) further includes a laser assembly (60) operable to deliver a melting laser beam (64a), to melt and fuse the powder (24) used to build the one or more parts (22). The AM apparatus (10) further includes a part detachment assembly (80), separate from the laser assembly (60) and operable for a cutting operation (84). The part detachment assembly (80) includes one or more laser beam delivery apparatuses (90), each operable to deliver a cutting laser beam (92), and a part holder apparatus (120). During the cutting operation (84), the part holder apparatus (120) holds the one or more parts (22), and each of the laser beam delivery apparatus(es) (90) delivers the cutting laser beam (92), to detach the one or more parts (22) from the build plate (28) within the AM apparatus (10).