Additive Metal Manufacturing with Additive Removal for Low Distortion
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Solution Overview
Problem
Conventional additive manufacturing techniques face challenges in reducing part distortion, improving resolution and surface finish, and managing geometry changes during metal piece production, particularly with soft solids and hybrid manufacturing systems.
Innovation Solution
The system employs a hybrid manufacturing technique that includes selective deposition of metal layers, removal of additives between deposition steps, and manipulation of material carriers to achieve near-net geometry, combined with controlled temperature and cooling methods to minimize distortion and enhance surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing techniques are used to deposit metal layers, then material can be added to form parts, but part distortion and geometry changes occur during manufacturing
Solution Approach 1:
The system performs preliminary actions by removing additives from material carriers between deposition steps, preparing the material in advance for the next deposition. This prevents distortion from accumulating and allows for better control of geometry changes, resolving the contradiction between precision and productivity
Solution Approach 2:
The system maintains continuous useful action by combining deposition, additive removal, and manipulation operations in an integrated workflow. The additive removal mechanism operates between deposition steps without interrupting the overall manufacturing flow, enabling continuous production while maintaining precision through intermediate processing
2Manufacturing precision
If additive removal is performed between deposition steps, then resolution and surface finish improve, but process complexity increases
Solution Approach 1:
The system merges the additive removal mechanism with the deposition system, integrating multiple functions into a unified manufacturing platform. This combination reduces overall process complexity while maintaining improved resolution and surface finish through intermediate additive removal steps
Solution Approach 2:
The manufacturing system is designed with multi-functionality, where the same system performs deposition, additive removal, and manipulation operations. This universal approach simplifies the overall process architecture while achieving superior resolution through the integrated additive removal capability
3Manufacturing precision
If material manipulation is performed to achieve near-net geometry, then manufacturing precision improves, but manufacturing time increases
Solution Approach 1:
The system performs preliminary manipulation of material carriers between deposition steps to achieve near-net geometry incrementally. This distributed approach to geometry achievement reduces the need for extensive post-processing while minimizing total manufacturing time through intermediate corrections
Solution Approach 2:
The manipulation operations are integrated into the continuous manufacturing workflow, occurring between deposition steps without significant interruption. This continuous approach achieves near-net geometry while maintaining efficient production timing through seamless operation integration
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 reduces part distortion, improves resolution and surface finish, and minimizes geometry changes, enabling the production of metal pieces with tighter tolerances and reduced manufacturing time.
Implementation Method 1
a deposition mechanism within a working volume to deposit a material carrier layer upon a workpiece
Implementation Method 2
an additive removal mechanism to remove an additive from the deposited material carrier layer
Implementation Method 3
controlled temperature and cooling methods to minimize distortion and enhance surface finish
Implementation Method 4
controlled temperature and cooling methods to minimize distortion and enhance surface finish
Data Source
AI summary
A system for additive metal manufacturing, including a deposition mechanism, a translation mechanism mounting the deposition mechanism to the working volume, and a stage. A method for additive metal manufacturing including: selectively depositing a material carrier within the working volume; removing an additive from the material carrier; and treating the resultant material.