Direct Print Mold Fixturing With Reinforcement for Stress Cracking
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Solution Overview
Problem
Conventional mold techniques for manufacturing turbine components are time-consuming and limit the resolution of the mold and core, while additive manufacturing techniques can create complex shapes but often result in stress features that lead to cracking or deformation of the mold.
Innovation Solution
The method involves evaluating flaws in existing molds, adding external reinforcement features such as external ribbing and gussets to the mold design, manufacturing the improved mold using additive manufacturing, and casting the component in the reinforced mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing techniques are used to manufacture molds, then manufacturing speed and efficiency are improved, but stress features cause cracking or deformation of the mold
Solution Approach 1:
The patent applies local quality by adding reinforcement features (ribs, gussets, strengthening elements) to specific high-stress areas of the mold design. These localized structural enhancements are positioned based on finite element analysis to provide exactly where needed without adding unnecessary weight or complexity elsewhere in the mold structure.
Solution Approach 2:
The patent employs composite materials by combining ceramic materials with reinforcement features made from different materials or structures. The mold comprises a ceramic base material with integrated reinforcement elements that may be made from metal alloys or other ceramic compositions, creating a composite structure that leverages the advantages of each material.
2Strength
If conventional mold techniques are used, then mold strength is maintained, but manufacturing time increases and resolution is limited
Solution Approach 1:
The patent applies preliminary action by incorporating reinforcement features directly into the mold design during the additive manufacturing process. Rather than adding reinforcements after mold fabrication, the strengthening elements are built in during the initial printing process, eliminating subsequent manufacturing steps and reducing overall production time.
Solution Approach 2:
The patent employs parameter changes by optimizing the geometry, distribution, and dimensions of reinforcement features through finite element analysis and iterative design. This allows the mold to achieve conventional strength levels with optimized reinforcement parameters rather than using excessive material or traditional manufacturing methods.
3Strength
If reinforcement features are added to improve mold strength, then stress concentrations are reduced, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating reinforcement features directly into the mold's structural design rather than treating them as separate components. The ribs, gussets, and strengthening elements are merged with the mold body in a unified additive manufacturing process, eliminating the need for separate assembly steps and reducing overall device complexity despite the increased structural detail.
Data Source
AI summary
A method of optimizing strength in an improved mold for a cast component. The method may include the steps of evaluating a flaw in an existing mold, adding external reinforcement features to a design of the improved mold, manufacturing the improved mold in an additive manufacturing process, and casting the cast component in the improved mold.