Additive Manufacturing Energy Mapping for Uniform Part Consolidation
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Solution Overview
Problem
Additive manufacturing processes face challenges in achieving uniform energy application across a manufactured component, leading to non-uniformities due to varying energy requirements at different locations, resulting in defects and property variations within the component.
Innovation Solution
The method involves determining an energy application parameter at each addition location based on factors like thermal energy dissipation, angle of incidence, and material properties, and delivering energy accordingly to form a melt pool that is consolidated with the previously formed portion of the component, using a system comprising a support platform, feedstock supply, and an energy source controlled by a controller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed amount of energy is applied during additive manufacturing, then the process is simple to control, but non-uniformities are produced in the manufactured component due to varying energy requirements at different locations
Solution Approach 1:
The patent applies local quality by determining location-specific energy application parameters based on the overlap volume between the virtual geometric shape and previously formed portions at each addition location. This allows different amounts of energy to be delivered to different locations according to their specific thermal characteristics, achieving uniform manufacturing results while accounting for local variations in heat dissipation
Solution Approach 2:
The patent implements preliminary action by pre-determining the energy application parameter for each addition location before actual manufacturing based on the overlap volume calculation. This predictive approach allows the system to compensate for anticipated thermal variations at each location, ensuring uniform energy distribution throughout the manufactured component
2Reliability
If too much energy is applied in some areas during additive manufacturing, then material consolidation is improved, but defects are created due to excessive energy input
Solution Approach 1:
The patent implements feedback by using the calculated overlap volume as a basis for determining the appropriate energy application parameter at each addition location. This feedback mechanism ensures that energy delivery is adjusted according to the actual thermal conditions and geometric characteristics of each location, preventing both under-consolidation and over-energy defects
3Loss of energy
If too little energy is applied in other areas during additive manufacturing, then energy waste is reduced, but non-uniformities are produced in the manufactured component
Solution Approach 1:
The patent applies local quality by calculating the overlap volume at each specific addition location and using this information to determine the precise energy application parameter needed. This ensures that each location receives exactly the amount of energy required for proper consolidation, avoiding both energy waste and manufacturing non-uniformities
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 ensures more uniform energy application and material properties across the component, reducing defects and improving the overall quality of the manufactured part by adjusting energy delivery based on location-specific parameters.
Implementation Method 1
delivering, from an energy source and to the addition location, an amount of energy sufficient to form a melt pool of the feedstock material at the addition location
Implementation Method 2
consolidating the melt pool with a previously formed portion of the manufactured component to form an additional portion of the manufactured component
Data Source
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AI summary
Methods of additively manufacturing a manufactured component and systems that perform the methods. The methods include determining an energy application parameter at an addition location (94) on a previously formed portion (92) of the manufactured component. The energy application parameter includes an overlap volume (82) between a virtual geometric shape, which is positioned at the addition location, and the previously formed portion of the manufactured component. The methods also include supplying a feedstock material to the addition location. The methods further include delivering, from an energy source and to the addition location, an amount of energy (42) sufficient to form a melt pool of the feedstock material at the addition location. The amount of energy is based, at least in part, on the energy application parameter. The methods also include consolidating the melt pool with a previously formed portion of the manufactured component to form an additional portion of the manufactured component.