Selective Melting Secondary Elements for Powder Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing molding elements using selective melting, such as sintering, are costly due to excessive powder consumption and limited secondary element utilization, as they require melting a large quantity of powder and the secondary elements are often scrapped after use.
Innovation Solution
The manufacturing process involves creating a main element and secondary elements simultaneously, with secondary elements having a body connected to the support plate and a head connected to the main element, featuring a region of connection between the head and body, and a head that extends over at most half the height of the secondary element, to enhance mechanical integrity and reduce powder consumption, while also providing means for easy detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If secondary elements are produced with sufficient thickness to ensure mechanical integrity during sintering, then the mechanical strength is improved, but the powder consumption increases and manufacturing cost rises
Solution Approach 1:
The secondary element is divided into two distinct parts: a body portion with thickness E connected to the support plate, and a head portion with width L connected to the main element. This segmentation allows each part to have optimized thickness for its specific function, reducing overall powder consumption while maintaining mechanical integrity where needed.
Solution Approach 2:
Different regions of the secondary element have different thicknesses tailored to their functional requirements. The body has thickness E for structural support, while the head has width L for connection to the main element. This local differentiation ensures mechanical integrity is provided only where necessary, minimizing unnecessary powder consumption.
2Reliability
If secondary elements are designed with sufficient thickness to withstand stress during manufacturing, then the reliability is improved, but the manufacturing cost increases due to excessive powder usage
Solution Approach 1:
The secondary element is segmented into a body of thickness E that withstands manufacturing stress, and a head of width L that connects to the main element. This segmentation ensures reliability is maintained in the body portion while minimizing powder consumption in the head portion.
Solution Approach 2:
The body portion is given sufficient thickness E to withstand stress during manufacturing, while the head portion has reduced width L for connection purposes. This local quality differentiation ensures reliability where needed without excessive powder consumption elsewhere.
3Strength
If the head of the secondary element extends over a large portion of the element height, then the connection strength to the main element is improved, but the powder consumption and manufacturing cost increase
Solution Approach 1:
The secondary element is segmented into a body of thickness E and a head of width L, where the head extends over at most half the height H of the secondary element. This segmentation provides sufficient connection strength while limiting powder consumption by restricting the head's vertical extent.
Solution Approach 2:
The head portion is designed with width L and limited vertical extension (at most H/2) to provide adequate connection strength to the main element while minimizing powder consumption. The body portion compensates for the reduced head size with sufficient thickness E.
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 reduces powder consumption, enhances mechanical integrity, and facilitates easier detachment of the main element from the support plate, thereby optimizing the use of secondary elements and lowering manufacturing costs.
Implementation Method 1
a first layer of powder is spread on a support plate by a layering member. All or some of the particles of powder of this first layer of powder are then agglomerated by the laser beam according to the shape of the object that is to be obtained
Implementation Method 2
A sintering method using a laser, hereinafter referred to as a laser sintering method
Data Source
AI summary
A part obtained by selective melting of a powder on a support plate having a main element and rigid secondary elements arranged between the main element and the support plate, and adapted to be detached from the main element. All or part of the secondary elements comprises a body of thickness E and a head of width L greater than the thickness E of this body, the body connected to the support plate and the head connected to main element. All or part of the secondary elements includes a region of connection between the head and the body. The head of the secondary element extends over at most half the height H of this element.