Multi-Face Additive Finishing with Simultaneous Energy Beams
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Solution Overview
Problem
Existing additive manufacturing systems face challenges in efficiently consolidating and finishing components with multiple faces of different orientations, as they typically require separate processes and support structures for each face, increasing time, cost, and material usage.
Innovation Solution
An additive manufacturing system with dual consolidation devices that can simultaneously direct energy beams at different orientations of a component, allowing for the consolidation and finishing of multiple faces without a surrounding powder bed or support structures, by positioning the devices circumferentially around the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single consolidation device is used to finish one face of the component, then the focused energy source can consolidate the powdered metal and finish the component on that face, but additional time and separate processes are required to consolidate and finish other faces of the component
Solution Approach 1:
The patent combines multiple consolidation devices into a single additive manufacturing system, allowing simultaneous consolidation and finishing of multiple faces. The system integrates a first consolidation device for a first face and a second consolidation device for a second face, both operating concurrently under unified control, thereby improving productivity while maintaining manufacturing precision across all faces.
Solution Approach 2:
The patent enables continuous useful action by allowing multiple consolidation devices to operate simultaneously on different faces of the component. While one device consolidates particles on a first face, another device concurrently consolidates particles on a second face, eliminating idle time and ensuring continuous productive operation throughout the manufacturing process.
2Manufacturing precision
If separate processes and support structures are used for each face, then each face can be consolidated and finished, but the time, cost, and raw materials required increase
Solution Approach 1:
The patent merges multiple separate consolidation processes into a single integrated system. Instead of sequentially processing each face with separate equipment and support structures, the system combines multiple consolidation devices that simultaneously operate on different faces, eliminating the need for repeated setup, support structure installation, and process sequencing, thereby reducing manufacturing cycle time while maintaining consolidation quality.
Solution Approach 2:
The patent implements preliminary action by positioning multiple consolidation devices in advance to access different faces of the component simultaneously. The devices are pre-configured with appropriate orientations and energy beam parameters before the consolidation process begins, allowing immediate concurrent operation without sequential setup delays that would otherwise be required for each face.
3Manufacturing precision
If the focused energy source is positioned to direct energy toward only one face, then consolidation and finishing can be achieved on that face, but the system cannot simultaneously consolidate and finish other faces with different orientations
Solution Approach 1:
The patent applies universality by designing consolidation devices that can be positioned and oriented to handle multiple faces of the component. The system includes a first consolidation device configured for a first face and a second consolidation device configured for a second face, where each device can be adjusted to direct energy beams at different orientations, enabling the system to universally process various face configurations simultaneously with high consolidation quality.
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 the time, costs, and raw materials required for manufacturing by enabling the simultaneous consolidation and finishing of multiple faces, eliminating the need for additional manufacturing steps and support structures.
Implementation Method 1
a consolidation device positioned about a component such that the energy beam is directed toward a face of the component... direct an energy beam along a scan path to a face of the component... consolidate particles along the scan path
Data Source
AI summary
An additive manufacturing system includes a build platform, at least one first consolidation device, and at least one second consolidation device. The at least one first consolidation device is configured to direct at least one first energy beam to a first face of a component. The first face has a first orientation. The at least one second consolidation device is configured to simultaneously direct at least one second energy beam toward a second face of the component as the first consolidation device directs the at least one first energy beam toward the first face. The second face has a second orientation different from the first orientation.