Manufacturing Chain Control for Consistent Additive Workpiece Output

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Solution Overview

Problem

Existing additive manufacturing technologies face challenges in ensuring consistent production of workpieces across different manufacturing chains due to varying parameters, leading to unacceptable variations in final products, especially when using different manufacturing bureaus.

Innovation Solution

A processor-based system that generates instructions for machines in a manufacturing chain by receiving a model-based definition of a workpiece, determining the additive build design, and adapting further instructions for downstream machines to compensate for differences in the additive build process, including support removal, material properties, and tolerances, to ensure consistent output.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If different additive build parameters are used in different manufacturing bureaus, then user flexibility and adaptability are improved, but manufacturing precision and product consistency deteriorate

Engineering Contradiction:

Improveuser flexibilityVSAvoidproduct consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system changes parameters of the downstream manufacturing process to compensate for variations in additive build parameters. The instruction generation apparatus receives additive build parameters, determines the intermediate workpiece characteristics, and adjusts downstream process parameters accordingly to achieve consistent final product quality across different manufacturing bureaus

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system establishes a feedback loop where the additive build parameters and intermediate workpiece characteristics inform the configuration of downstream processes. The instruction generation apparatus uses the determined differences between prospective intermediate workpiece and final workpiece to generate adapted instructions for downstream machines, ensuring consistent outcomes despite upstream variations

Inventive Principle:

Principle #23Feedback

2Productivity

If additive build design variables are changed to optimize the additive process, then productivity and ease of manufacture are improved, but manufacturing precision of the final workpiece deteriorates

Engineering Contradiction:

Improveadditive build efficiencyVSAvoidworkpiece tolerance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary determination of the intermediate workpiece characteristics and calculates the required adjustments for downstream processes before actual downstream manufacturing begins. The instruction generation apparatus pre-computes the adapted instructions based on additive build parameters, allowing downstream processes to be optimally configured in advance to compensate for expected variations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes parameters of downstream manufacturing processes based on the determined differences caused by additive build variable changes. By adjusting downstream process parameters in response to additive build configurations, the system maintains final workpiece precision even when additive productivity is optimized through parameter changes

Inventive Principle:

Principle #35Parameter changes

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 allows for the production of nominally identical workpieces even with differing additive build parameters, reducing variations and enhancing user flexibility by generating adapted instructions for machines in the manufacturing chain, thereby addressing concerns of inconsistent outputs across different manufacturing setups.

Implementation Method 1

a laser beam is scanned across portions of the powder layer that correspond to a cross-section (slice) of the workpiece being constructed. The laser beam melts or sinters the powder to form a solidified layer.

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

The laser beam melts or sinters the powder to form a solidified layer.

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

The laser beam melts or sinters the powder to form a solidified layer.

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS10983504B2Control of a chain of machines, including an additive manufacturing machine, in the manufacture of a workpiece

Publication Date: 2021.04.20 RENISHAW PLC

AI summary

This invention concerns apparatus for generating instructions for machines of a manufacturing chain used to manufacture a workpiece. The apparatus comprising a processor arranged to receive a model based definition (MBD) of a workpiece including geometric dimensions and tolerances; receive inputs setting an additive build design for building the workpiece based upon the geometric dimensions; generate additive instructions for an additive manufacturing machine of the manufacturing chain based upon the additive build design; determine a prospective intermediate workpiece product expected from an additive build in accordance with the additive build design; determine differences between the prospective intermediate workpiece product and the model based definition of the workpiece; and generate further instructions for at least one further machine of the manufacturing chain based upon the differences.