Porous Structure Sintering with Central-Axis CNC Paths

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for manufacturing porous structures through additive manufacturing, such as powder bed fusion, are time-consuming and complex, requiring significant computational resources and operational time, especially when generating CNC code for sintering paths, which affects the efficiency and cost of producing high-quality porous structures.

Innovation Solution

The method involves simplifying the sintering process by generating CNC code that focuses on sintering along a central axis of struts instead of tracing complex perimeter and interior paths, reducing computational time and operational hours required for manufacturing porous structures, and optimizing CNC code file sizes to enhance processing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional powder bed fusion techniques are used to manufacture porous structures, then manufacturing precision and product consistency are improved, but manufacturing time and operational complexity increase significantly

Engineering Contradiction:

Improveporous structure qualityVSAvoidmanufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent extracts and eliminates unnecessary sintering operations by recognizing that only the central axis of struts requires sintering to maintain structural integrity, while perimeter and interior paths can be omitted. This extraction of essential vs. non-essential sintering operations directly reduces manufacturing time while preserving porous structure quality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of following the conventional approach of sintering along complex perimeter and interior paths, the patent inverts the strategy by sintering only along the central axis of struts. This inverted approach achieves the same structural integrity with significantly reduced computational time and operational complexity.

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If complex CNC code is generated for traditional sintering paths, then manufacturing precision is maintained, but computational time and code complexity increase

Engineering Contradiction:

Improvesintering accuracyVSAvoidcomputational time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent extracts only the essential sintering paths along the central axis of struts, eliminating unnecessary perimeter and interior path calculations. This extraction reduces CNC code complexity and computational time while maintaining sufficient sintering accuracy for structural integrity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent inverts the conventional sintering path generation approach by calculating paths from the central axis outward rather than from the perimeter inward. This inversion simplifies the mathematical calculations required for CNC code generation while maintaining manufacturing precision.

Inventive Principle:

Principle #13The other way round (Inversion)

3Strength

If traditional sintering methods are used, then structural integrity is ensured, but operational time and manufacturing cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidoperational time

Core Design Contradiction:

StrengthVSDuration of action of moving object

Solution Approach 1:

The patent extracts the essential sintering operations limited to central axis paths, removing redundant perimeter and interior sintering steps. This extraction maintains structural integrity through proper sintering of load-bearing central regions while reducing operational time and manufacturing cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies local quality by differentiating sintering requirements between different regions of the porous structure. Central axis regions receive full sintering attention to ensure structural integrity, while perimeter and interior regions are omitted or minimized, optimizing the balance between strength and operational efficiency.

Inventive Principle:

Principle #3Local 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 significantly reduces the time and cost associated with manufacturing porous structures by minimizing computational and operational time, allowing for faster production of high-quality parts with reduced CNC code complexity and file sizes, thereby improving the overall efficiency of the additive manufacturing process.

Implementation Method 1

Powder bed fusion techniques such as laser sintering metal powder are often used

Methodology Applied

Scientific EffectLaser sintering: Laser Beam Welding

Implementation Method 2

The computer directs a sintering beam to sinter the part in a powder bed additive manufacturing machine layer by layer

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS11498124B1Method for sintering porous structures from powder using additive manufacturing

Publication Date: 2022.11.15 ORTHO DEV CORP

AI summary

A novel process for creating porous structures via powder bed fusion additive manufacturing is provided. The process reduces the computational requirement for generation of the porous structure geometry and for processing the porous structure geometry to generate CNC code. The process provides reduced file size for CNC code and avoids large files which may exceed capacity of manufacturing machines. The process also significantly reduces the time required to sinter the porous structure on a powder bed fusion manufacturing machine.