Multi-Walled AM Structures With Powder Removal Passages
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Solution Overview
Problem
Additive manufacturing techniques face challenges in creating multi-walled structures due to the retention of unfused powder in narrow passages, which is difficult to remove and can become sintered during post-processing, compromising the removal process.
Innovation Solution
Incorporating powder removal features, such as semi-annular or non-linear channels, into the multi-walled structures during fabrication to facilitate the extraction of unfused powder, which can be enhanced by vibration, rotation, and the use of compressed gas and vacuum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-walled structures are fabricated using additive manufacturing, then complex components with structural strength and airflow ducts can be created, but unfused powder becomes retained in narrow passages and is difficult to remove
Solution Approach 1:
The patent incorporates powder removal features directly into the multi-walled structure during the additive manufacturing process, before finalization. These features include enlarged internal spaces, access holes, and channels that provide pathways for powder extraction. By preparing these removal pathways in advance during fabrication, the patent enables effective powder removal without compromising the structural integrity of the final component.
2Reliability
If post-processing procedures are applied to finish the part, then thermal and chemical treatments can be performed, but retained powder becomes sintered and removal becomes even more difficult
Solution Approach 1:
The patent emphasizes removing unfused powder from narrow passages before thermal post-processing procedures are applied. By implementing powder removal features and extraction methods during or immediately after fabrication, the patent prevents powder sintering that would occur during subsequent thermal treatments, thereby maintaining both post-processing capability and powder removal ease.
3Strength
If narrow passages are created in multi-walled structures, then structural strength and compact design are achieved, but powder retention in these passages increases
Solution Approach 1:
The patent divides the internal space of multi-walled structures into manageable sections using powder removal features. These features create enlarged spaces and access points that segment the narrow passages, allowing powder to be accessed and removed from specific regions without compromising the overall structural strength of the compact design.
Solution Approach 2:
The patent introduces powder removal features as intermediary elements within the multi-walled structure. These features include access holes and channels that serve as mediators between the narrow internal passages and the external environment, enabling powder extraction while maintaining the structural integrity of the original design.
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
Effectively removes unfused powder with minimal structural weakening and provides additional structural support, while allowing for precise fabrication of complex components.
Implementation Method 1
uses an energy beam, for example, an electron beam or electromagnetic radiation such as a laser beam, to sinter or melt a powder material
Implementation Method 2
sintering entails fusing (agglomerating) particles of a powder at a temperature below the melting point of the powder material
Implementation Method 3
melting entails fully melting particles of a powder to form a solid homogeneous mass
Implementation Method 4
which can be enhanced by vibration, rotation, and the use of compressed gas and vacuum
Implementation Method 5
which can be enhanced by vibration, rotation, and the use of compressed gas and vacuum
Implementation Method 6
which can be enhanced by vibration, rotation, and the use of compressed gas and vacuum
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present disclosure generally relates to methods for additive manufacturing (AM) for fabricating multi-walled structures. A multi-walled structure includes a first wall having a first surface and a second wall having a second surface facing the first surface to define a passage having a width between the first surface and the second surface in a first direction. The multi- walled structure also includes an enlarged powder removal feature connecting the first wall and the second wall. The enlarged powder removal feature has an inner dimension greater than the width in the first direction and at least one open end in a direction transverse to the first width.