Additive Manufacturing Shell-Core Segmentation for Surface Quality
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Solution Overview
Problem
Additive manufacturing processes are not economically viable for series production in price-sensitive markets due to high component costs, long production times, and high material costs, primarily because of complex production processes and surface reworking efforts.
Innovation Solution
A method involving the shell-core principle in additive manufacturing, where a 3D data set is divided into an envelope area and a core area, allowing for different process parameters and mechanical properties, with the use of vibrations and sintering to enhance density and reduce production time, and a calibration process to achieve lower surface roughness and porosity for efficient resource use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional solidification methods are used in additive manufacturing, then surface quality is improved, but production time increases significantly
Solution Approach 1:
The component model is divided into two distinct regions: a shell area with higher surface quality requirements and a core area with lower surface quality requirements. This segmentation allows different process parameters to be applied to each region, optimizing both surface quality and production efficiency.
Solution Approach 2:
Different laser process parameters are applied locally to different regions of the component. The shell area receives parameters optimized for surface quality (lower laser power, thinner layers), while the core area receives parameters optimized for build speed (higher laser power, thicker layers).
2Productivity
If higher laser power and greater layer thicknesses are used to increase build rate, then productivity is improved, but surface roughness increases
Solution Approach 1:
The build volume is segmented into shell and core regions, allowing independent optimization of process parameters for each region. The shell region uses parameters that produce smooth surfaces, while the core region uses parameters that maximize build rate.
Solution Approach 2:
The laser process parameters are localized to specific regions. High laser power and thick layers are applied only where surface quality is not critical (core area), while low laser power and thin layers are applied where surface quality matters (shell area).
3Productivity
If openings are provided for powder removal and metal filling in shell-core manufacturing, then productivity is improved, but device complexity increases
Solution Approach 1:
The system uses the existing powder feed mechanism to serve dual purposes: delivering powder for solidification in the shell area and filling the core area. The same powder delivery infrastructure performs multiple functions, reducing the need for additional complex equipment.
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 production time and material costs, enabling the production of components with improved mechanical properties and surface quality, making additive manufacturing more competitive for series production by optimizing the use of metallic powders and enhancing the density of the final product.
Implementation Method 1
successive hardening of parts of the powder layers to form at least one predetermined structure in the superimposed powder layers
Implementation Method 2
with the use of vibrations and sintering to enhance density and reduce production time
Implementation Method 3
with the use of vibrations and sintering to enhance density and reduce production time
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for producing a body by means of an additive production method (AM) by using metal powder, comprising the following steps: designing the body in a computer-simulated manner while taking into account at least one region of the body to be processed and transferring data to an additive production device, in particular an additive powder-bed production device, successively providing the metal powder in order to construct powder layers arranged one on the other, successively hardening parts of the powder layers in order to form at least one specified structure in the powder layers arranged one on the other, wherein the structure is at least partially filled with metal powder of the powder layers, and calibrating a body, which is created by means of the structure, in the region to be processed. The invention further relates to a corresponding device, to a body produced in such a way, and to a computer program product for performing the method.