Rotating Build Platform for Hollow 3D Metal Structures
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Solution Overview
Problem
The Laser Metal Deposition (LMD) method faces challenges in manufacturing three-dimensional shaped objects with hollow portions, as the formation of new solidified layers is physically difficult without a platform of solidified layers underneath, making it hard to create objects with internal hollow structures.
Innovation Solution
The method involves forming a solidified foundation portion as a platform for subsequent layers and changing its orientation to allow the formation of new solidified layers on its lateral sides, enabling the creation of hollow portions within the three-dimensional shaped object by concurrent raw material supply and light beam irradiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If LMD method is used to manufacture three-dimensional shaped objects with hollow portions, then productivity is improved by concurrent raw material supply and light beam irradiation, but manufacturing precision deteriorates because formation of new solidified layers is physically difficult without a platform of solidified layers underneath
Solution Approach 1:
The invention changes the building direction of solidified layers from a single vertical direction to multiple directions by rotating the build platform. This allows subsequent layers to be formed on lateral sides of previously formed foundation portions, enabling creation of hollow portions and complex three-dimensional structures that cannot be achieved with conventional single-direction layer formation.
Solution Approach 2:
The build platform is made rotatable to dynamically change the orientation of solidified foundation portions during the manufacturing process. This dynamic reorientation allows the formation of subsequent layers on different surfaces (lateral sides) of the foundation portions, solving the problem of forming hollow structures while maintaining manufacturing precision.
2Manufacturing precision
If powder bed fusion is used to provide higher accuracy of form/shape of solidified layer, then manufacturing precision is improved, but productivity deteriorates due to longer time required for formation of solidified layer
Solution Approach 1:
The invention forms solidified foundation portions first as platforms, then rotates the build platform to orient these foundations for subsequent layer formation. This preliminary action of creating stable foundation portions followed by orientation change enables efficient layer formation without requiring time-consuming alternate repetition of powder layer forming and solidified layer forming.
Solution Approach 2:
The LMD method with platform rotation enables continuous formation of solidified layers by maintaining the build platform rotation and continuously supplying raw material while irradiating with light beam. This continuous process eliminates the idle time between powder layer formation and solidified layer formation, improving productivity while maintaining precision through the controlled rotation mechanism.
3Device complexity
If conventional LMD method is used without platform rotation, then device complexity is reduced, but adaptability deteriorates because hollow portions cannot be formed in three-dimensional shaped objects
Solution Approach 1:
A rotatable build platform is introduced to dynamically change the orientation of solidified foundation portions during manufacturing. This dynamic capability enables the formation of hollow portions and complex three-dimensional structures by allowing subsequent layers to be deposited on lateral sides of foundations, significantly improving the adaptability of the LMD method.
Solution Approach 2:
The invention adds rotational movement to the build platform, transforming the layer formation process from single-direction (vertical stacking only) to multi-directional (vertical stacking plus lateral side formation through rotation). This dimensional change enables the creation of hollow portions and complex geometries that are impossible with conventional static platform LMD.
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 allows for the suitable manufacturing of three-dimensional shaped objects with hollow portions, improving the ability to form complex structures and enhancing the structural strength and heat exchange efficiency when used as metal molds.
Implementation Method 1
irradiating a raw material with a light beam at the time of suppling the raw material, thereby allowing a sintering of the raw material or a melting and subsequent solidification of the raw material
Implementation Method 2
irradiating a raw material with a light beam at the time of suppling the raw material, thereby allowing a sintering of the raw material or a melting and subsequent solidification of the raw material
Data Source
AI summary
There is provided a method for manufacturing a three-dimensional shaped object by a continuous formation of a plurality of solidified layers through a light beam irradiation, the three-dimensional shaped object being provided with a hollow portion in an interior of the shaped object. The manufacturing method performs the formation of the solidified layer by irradiating a raw material with a light beam at the time of suppling the raw material, thereby allowing a sintering of the raw material or a melting and subsequent solidification of the raw material. In particular, a solidified foundation portion is provided as a part of the three-dimensional shaped object, the solidified foundation portion being used for a platform for a formation of a subsequent layer provided as the solidified layer. An orientation of the solidified foundation portion is changed prior to the formation of the subsequent solidified layer.