Mandrel-Supported 3D Printing for Round Hybrid Components
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in producing hybrid structures with complex geometries and large components due to limitations in accuracy, cost, and thermal stress deformation, particularly when combining different materials with varying thermal conductivity.
Innovation Solution
A hybrid manufacturing approach using multiple additive manufacturing techniques, such as powder-bed fusion and direct-energy deposition, combined with the use of a mandrel to maintain component roundness and rigidity during the formation of a second component, allowing for precise joining and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to produce large structures with complex geometries, then design freedom and manufacturing capability are improved, but manufacturing precision and roundness maintenance deteriorate due to thermal stress deformation
Solution Approach 1:
A mandrel is inserted into the additively manufactured component before the additive manufacturing process is completed. This preliminary action provides internal support structure that maintains the component's roundness and prevents thermal stress deformation during subsequent manufacturing operations, while still allowing the component to achieve complex geometries through additive manufacturing
2Adaptability or versatility
If multiple additive manufacturing techniques are combined to create hybrid structures, then design freedom and functionality are improved, but manufacturing complexity and process control difficulty increase
Solution Approach 1:
The manufacturing process is segmented into distinct phases: first adding a mandrel to provide structural support, then performing additive manufacturing operations, and finally removing the mandrel. This segmentation allows complex hybrid structures to be manufactured through manageable steps, reducing overall process complexity while maintaining design freedom
Solution Approach 2:
The mandrel serves as an intermediary element during the manufacturing process. It provides the necessary structural support and roundness maintenance without being part of the final component, enabling the production of complex hybrid structures while simplifying process control by separating the support function from the final product
3Productivity
If additive manufacturing is used for large components, then manufacturing cost and productivity are improved compared to traditional methods, but manufacturing precision and joint integrity deteriorate due to thermal stress and deformation
Solution Approach 1:
The mandrel is inserted before the additive manufacturing process to establish proper structural support and dimensional accuracy. This preliminary action ensures that when multiple components are joined, the interfaces maintain high precision and integrity, while still allowing efficient additive manufacturing production of large components
Data Source
AI summary
The disclosure presents a combination of additive manufacturing processes that could be used to produce different portions or features of a hybrid structure, such that a first additive manufacturing process could be used to form a complex seed part or first section of the hybrid component, and a different additive manufacturing component could be used to form a second section of the hybrid component. When two components are manufactured, a mandrel could be assembled into the first component to provide rigidity and resistance to deformation of the first component, even during and after formation of the second component on the interface surface of the first component using a second additive manufacturing process. Finally, struts could be formed directly on a base plate and before formation of the component so that the base plate temperature could increase to be in equilibrium with the temperature of the newly deposited material.