Sheet-Based Additive Manufacturing for Complex Parts Without Supports
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Solution Overview
Problem
Conventional additive manufacturing techniques face challenges in producing parts efficiently in terms of time, cost, and energy, and often result in poor surface finishes and the need for complex support structures, especially for parts with complex geometries.
Innovation Solution
A sheet-based additive manufacturing method involving the stacking of fusible materials and the use of a laser beam to fuse adjacent sheets according to a predetermined pattern, reducing the need for support structures and improving surface finish by forming a homogenous, monolithic construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional additive manufacturing techniques use powder or wire-fed materials, then parts can be produced with complex geometries, but the production time, cost, and energy consumption increase significantly
Solution Approach 1:
The patent replaces conventional mechanical additive manufacturing systems (powder or wire-fed) with a sheet-based system. Sheets of fusible material are stacked and fused using a laser beam, eliminating the need for complex powder handling and wire feeding mechanisms. This substitution reduces mechanical complexity and improves production efficiency while maintaining the ability to produce complex geometries.
Solution Approach 2:
The patent changes the physical state and form of the additive material from powder or wire to thin sheets. This parameter change enables more efficient material delivery and fusion processes, reducing production time and energy consumption while maintaining geometric complexity capabilities.
2Adaptability or versatility
If conventional additive manufacturing techniques use powder or wire-fed materials, then parts can be produced with complex geometries, but cost and energy consumption increase
Solution Approach 1:
The sheet-based system replaces energy-intensive powder or wire feeding mechanisms with a simpler stacking and laser fusion process. The laser beam directly fuses sheets at predetermined locations, reducing overall energy consumption compared to conventional techniques that require continuous material feeding and heating.
3Productivity
If conventional additive manufacturing techniques are used, then parts can be produced, but surface finish quality is poor
Solution Approach 1:
The patent changes the material form to thin sheets with smooth surfaces, which inherently provide better surface finish quality compared to powder or wire-fed materials. The sheet material's uniform thickness and smooth texture translate directly to improved part surface finish after fusion.
4Adaptability or versatility
If conventional additive manufacturing techniques are used for complex geometries, then parts can be produced, but complex support structures are required
Solution Approach 1:
The sheet-based fusion process replaces the need for complex support structures with a different manufacturing approach. Sheets are fused at predetermined locations using laser energy, creating stable structures through controlled fusion points rather than relying on extensive support frameworks.
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 method enhances time, cost, and energy efficiency while improving surface finish quality and reducing the need for complex support structures, enabling the production of parts with complex geometries.
Implementation Method 1
directing a laser beam through at least one sheet of the stack... Transferring energy from the laser beam to multiple locations on at least one interface between adjacent sheets of the stack... to form corresponding multiple molten regions
Implementation Method 2
to form corresponding multiple molten regions, conjoined together to form a fused portion of the adjacent sheets
Implementation Method 3
Transferring energy from the laser beam to multiple locations comprises focusing the laser beam at the multiple locations
Data Source
AI summary
A method of fabricating a part includes stacking sheets of fusible material to form a stack. The method also includes directing a laser beam through at least one sheet of the stack. The method also includes transferring energy from the laser beam to multiple locations on at least one interface between adjacent sheets of the stack, according to a predetermined pattern corresponding with a design of the part, to form corresponding multiple molten regions. The molten regions are conjoined together to form a fused portion of the adjacent sheets. The fused portion of the adjacent sheets defines the part.