Segmented Additive Manufacturing for Large Thin-Walled Components

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Solution Overview

Problem

Aerospace components with thin walls and complex geometries pose challenges for accurate additive manufacturing due to size limitations of conventional build chambers and the need for precise fastening schemes.

Innovation Solution

The method involves electronically segmenting a CAD file of the component along a build interface to define multiple segments that can fit within a smaller build chamber, allowing for simultaneous manufacturing and bonding of these segments, optionally with sacrificial material for dimensional adjustment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the component size is increased to meet aerospace requirements, then the component can satisfy functional requirements, but the component cannot fit within the conventional build chamber

Engineering Contradiction:

Improvecomponent sizeVSAvoidbuild chamber capacity

Core Design Contradiction:

Volume of moving objectVSArea of stationary object

Solution Approach 1:

The component is divided into multiple segments along a build interface, allowing each segment to be manufactured separately within the build chamber constraints while the final assembled component achieves the required large size

Inventive Principle:

Principle #1Segmentation

2Shape

If the component geometry is made complex to satisfy aerospace functional requirements, then the component can achieve desired performance, but the manufacturing accuracy decreases

Engineering Contradiction:

Improvecomponent geometryVSAvoidmanufacturing accuracy

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

Complex geometries are divided into manageable segments with simplified individual features, allowing each segment to be manufactured with higher precision while maintaining the overall complex geometry through assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Sacrificial material is added in advance during segment manufacturing to compensate for dimensional variations, and this sacrificial material is later removed to achieve the final precise dimensions

Inventive Principle:

Principle #10Preliminary action

3Weight of moving object

If the component walls are made thin to reduce weight, then the component weight decreases, but the manufacturing difficulty increases

Engineering Contradiction:

Improvecomponent weightVSAvoidmanufacturing difficulty

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

Thin-walled components are segmented to allow each section to be manufactured with controlled wall thickness, reducing the difficulty of manufacturing while maintaining weight efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Sacrificial material is strategically added to thin-walled segments during manufacturing to ensure proper dimensional control, and is subsequently removed to achieve the final thin-walled structure

Inventive Principle:

Principle #10Preliminary action

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 enables the additive manufacturing of large aerospace components by allowing them to be built in smaller sections, improving manufacturing accuracy and efficiency while accommodating complex geometries and thin walls.

Implementation Method 1

additive manufacturing processes typically use 3D CAD data and an energy source such as high powered laser beam to form three-dimensional metal parts by fusing fine metallic powders

Methodology Applied

Scientific EffectLaser heating and melting: Laser

Implementation Method 2

The bonding of the first component segment and the second component segment may include welding

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS12314033B2Additive manufacturing system and method of manufacture

Publication Date: 2025.05.27 RTX CORP

AI summary

An additive manufacturing method includes segmenting a CAD file of a component along a build interface to define at least a first component segment and a second component segment, each of the first component segment and the second component segment sized to fit within an additive manufacturing build chamber; additive manufacturing the first component segment and the second component segment within the build chamber; and bonding the first component segment and the second component segment to form the component.