3D Printing of Revolution Parts Using a Rotating Core
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Solution Overview
Problem
Existing additive-manufacturing machines struggle to efficiently produce revolution parts, particularly those with complex geometries like camshafts or crankshafts, due to high complexity and cost, especially when using Selective Laser Sintering (SLS) or Electron Beam Melting (EBM) technologies.
Innovation Solution
A system comprising a core element with an axis of revolution and an additive-manufacturing machine with a movable additive head capable of translational and rotational movements along x, y, and z directions, allowing the deposition of additive material onto the core to form revolution parts, including those with 90° edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive-manufacturing machines (Cartesian, Parallelogram, 45° Cartesian, or Robotic arm) are used to manufacture revolution parts, then manufacturing capability is provided, but device complexity and cost increase significantly
Solution Approach 1:
The system segments the revolution part manufacturing into two distinct phases: first manufacturing a simple core element with the desired external geometry, then adding a reinforcement skin layer. This segmentation allows each phase to be optimized independently, using simpler machine configurations for core manufacturing while adding complexity only where necessary for reinforcement
Solution Approach 2:
The core element serves as an intermediary object that simplifies the manufacturing process. By creating a core with the basic external geometry first, the system reduces the complexity requirements of the initial manufacturing stage, and the core acts as a foundation for subsequent reinforcement skin deposition
2Manufacturing precision
If Selective Laser Sintering (SLS) or Electron Beam Melting (EBM) technologies are used for revolution parts, then manufacturing precision is improved, but cost increases significantly
Solution Approach 1:
The system applies local quality by providing reinforcement only in specific areas where it is needed. The reinforcement skin is deposited selectively on the core element's surface, allowing enhanced precision and strength in critical regions while maintaining cost-effectiveness through the use of simpler FDM technology for the overall manufacturing process
3Ease of manufacture
If conventional additive-manufacturing machines are used for revolution parts with reinforced skin, then manufacturing capability is provided, but device complexity and cost increase
Solution Approach 1:
The system employs dynamic adjustment of the additive head's orientation angle relative to the core element's axis of revolution. This dynamic capability allows the head to be positioned at different angles during deposition, enabling the manufacturing of complex revolution parts with reinforced skins using a relatively simple machine configuration that can adapt its orientation rather than requiring complex multi-axis positioning systems
4Productivity
If conventional additive-manufacturing machines are used for revolution parts, then manufacturing capability is provided, but production cost increases
Solution Approach 1:
The system performs preliminary action by manufacturing the core element with the complete external geometry first, before adding the reinforcement skin. This preliminary core creation allows for optimized material usage and reduces the complexity of the overall process, as the core serves as a pre-formed foundation that simplifies subsequent skin deposition operations
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
Enables the cost-effective production of complex revolution parts with reduced complexity, enabling the use of cheaper Fuse Deposition Modeling (FDM) machines and allowing larger parts with lightweight cores and reinforced structures.
Implementation Method 1
an additive-manufacturing head for depositing additive material onto the core element
Data Source
Figure 1~3
Figure 4~5b
AI summary
The invention describes an additive-manufacturing system for the three dimensional printing of a revolution part, and a method for printing a three dimensional revolution part. The system comprises a core element (4) having an axis of revolution (A), and an additive-manufacturing machine comprising an additive-manufacturing head (1) movable along to three normal directions (x, y, z). The core element (4) is rotatably mounted about the axis of revolution (A) of the core element (4) in the additive-manufacturing machine; the additive-manufacturing head (1) is movably mounted along to both a linear translational movement in an horizontal x-direction, parallel to the axis of revolution (A) of the core element (4), and a linear translational movement along to a vertical y-direction; and the additive-manufacturing head (1) is also rotatably mounted about a z-direction to allow a normal deposition of the additive material onto the core element (4).