Segmented Additive Manufacturing for Large Thin-Walled Components
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Solution Overview
Problem
Aerospace components with thin walls and complex geometries, such as those in gas turbine engines, pose challenges for accurate additive manufacturing due to size limitations and the need for precise fastening schemes, often requiring subsequent machining and additional hardware for orientation.
Innovation Solution
The method involves electronically segmenting a CAD file to define component segments that fit within a build chamber, allowing simultaneous additive manufacturing and bonding of these segments, with the option to add sacrificial material beyond the build interface for increased size and thickness, which is consumed during bonding to achieve the desired dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the component size is increased to accommodate complex aerospace structures, then the functional requirements are met, but the component cannot fit within the build chamber for additive manufacturing
Solution Approach 1:
The component is divided into multiple segments that can be manufactured separately within the build chamber and then assembled. This allows each segment to fit within the build chamber volume constraints while the final assembled component achieves the required large size and complex geometry for aerospace applications
2Shape
If the component geometry is made complex to meet aerospace design requirements, then the functional performance is improved, but the manufacturing accuracy and alignment become difficult to achieve
Solution Approach 1:
Alignment features and fastening schemes are designed and prepared in advance during the segmentation phase. By pre-planning the interface geometries and incorporating alignment features into each segment before manufacturing, the system ensures that complex geometries can be assembled with high precision without requiring excessive post-manufacturing machining or adjustment
3Temperature
If thin walls and enclosures are designed to meet aerospace cooling requirements, then the thermal performance is improved, but the structural integrity and manufacturing accuracy become compromised
Solution Approach 1:
The component is segmented in a way that allows thin-walled enclosures with cooling holes to be manufactured with adequate structural support in each segment. The segmentation strategy ensures that critical structural regions can be reinforced or supported during manufacturing while maintaining the required thin wall sections for cooling performance
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 accurate and efficient additive manufacturing of complex aerospace components by allowing them to be built in smaller chambers, reducing the need for subsequent machining and ensuring precise alignment, while maintaining the desired dimensions and internal structures.
Implementation Method 1
additive manufacturing processes typically use 3D CAD data and an energy source such as a high powered laser beam to form three-dimensional metal parts by fusing fine metallic powders
Implementation Method 2
the bonding of the first component segment and the second component segment may include welding
Data Source
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.