Modular Tray for Axis of Revolution Additive Manufacturing
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Solution Overview
Problem
The manufacturing of parts with an axis of revolution using additive manufacturing on a powder bed requires a large number of support elements and a separate operation to detach the part from the tray, which increases powder usage and processing time, especially for complex geometries like sprockets with varying diameters.
Innovation Solution
A modular tray system comprising a shaft-mounted circular module and a main support module, allowing localized melting or sintering on removable modules that can be machined directly on a lathe, reducing the need for extensive support elements and eliminating the need for separate detachment from a conventional tray.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional trays with multiple support elements are used for additive manufacturing of parts with axis of revolution, then the part can be manufactured with proper support, but the quantity of support elements increases significantly, impacting powder usage and lasering time
Solution Approach 1:
The tray is divided into multiple removable circular modules that can be independently positioned and removed. Each module can be selectively placed only where needed during manufacturing, allowing flexible support coverage with minimal powder consumption. The modular design enables precise control over support element placement to match actual part requirements.
Solution Approach 2:
The circular modules are designed to be removable and repositionable during the manufacturing process. This dynamic configuration allows the support structure to be adapted as needed, reducing unnecessary support elements and minimizing powder usage while maintaining adequate support capability for the part geometry.
2Reliability
If conventional trays with multiple support elements are used, then the part can be manufactured with proper support, but the lasering time increases significantly
Solution Approach 1:
The support structure is segmented into separate circular modules that can be independently positioned. This segmentation allows the laser to process only the necessary areas more efficiently, reducing overall lasering time while maintaining adequate support coverage through strategic module placement.
Solution Approach 2:
The circular modules can be pre-positioned and configured before the lasering process begins. This preliminary arrangement optimizes the support structure placement to match the part geometry, allowing the laser to work more efficiently without unnecessary support elements and reducing total processing time.
3Ease of manufacture
If conventional trays are used, then the part can be manufactured, but a separate detachment operation is required using saw or electroerosion, increasing processing time and complexity
Solution Approach 1:
The tray is segmented into removable circular modules that can be easily detached from the main tray body. This segmentation eliminates the need for complex detachment operations using saws or electroerosion machines, as the modules can be simply removed from their cavities in the main tray, significantly reducing processing time and operational complexity.
Solution Approach 2:
The circular modules are designed as extractable components that can be easily removed from the main tray after manufacturing. This extraction capability eliminates the need for time-consuming detachment operations, allowing rapid removal of support elements and part separation without requiring specialized detachment equipment or complex processing steps.
4Adaptability or versatility
If a large quantity of support elements are used, then complex geometries like sprockets with varying diameters can be manufactured, but the quantity of support elements becomes significant, impacting both powder usage and processing time
Solution Approach 1:
The support structure is segmented into multiple circular modules that can be independently positioned and removed. This segmentation provides flexibility in configuring support elements to match complex part geometries like sprockets with varying diameters, while minimizing the total number of support elements needed by placing modules only where specifically required.
Solution Approach 2:
The circular modules are designed to be dynamically repositionable and removable, allowing the support configuration to be adapted to different part geometries. This dynamic capability enables versatile manufacturing of complex shapes like sprockets while keeping the quantity of support elements minimal by strategically placing and removing modules as needed.
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 significantly reduces the quantity of support elements needed, decreases lasering and machining time, and minimizes powder usage, while avoiding exposure to corrosion during the detachment process, resulting in a 27-38% saving in mass and time compared to conventional methods.
Implementation Method 1
These support elements are created, like the part, by localised melting or localised sintering (by means of a laser beam or a beam of electrons) of the powder during the formation of the part
Implementation Method 2
These support elements are created, like the part, by localised melting or localised sintering (by means of a laser beam or a beam of electrons) of the powder during the formation of the part
Data Source
AI summary
A modular tray, for the additive manufacturing of a part with an axis of revolution on a powder bed, includes: a shaft-mounted circular module including a shaft provided with a circular tray at one of the ends thereof, the shaft and the circular tray being concentric; and a main support module including, in one face, a cavity configured for receiving the shaft-mounted circular module, the shaft being completely inserted in the cavity. The assembly of the shaft-mounted circular module and of the main support module define a planar top surface that is at least partly formed by the circular tray of the shaft-mounted circular module.