SLM Component Adaptation via Correction Factors and Geometry
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Solution Overview
Problem
Selective laser melting methods often result in overhangs, step effects, and powder adhesions, particularly in components with stringent measurement accuracy requirements like gas turbine components, necessitating additional finishing steps.
Innovation Solution
An adaptation method that uses a target geometry to derive a model geometry, applying correction factors and geometries to compensate for overhangs and step effects, allowing for dimensional and geometrical adaptations based on orientation, dimension, and configuration, thereby eliminating the need for additional finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If selective laser melting method is used to produce components, then production efficiency and design freedom are improved, but manufacturing precision deteriorates due to overhangs, step effects and powder adhesions
Solution Approach 1:
The patent applies preliminary action by pre-compensating for expected deformations and geometric inaccuracies during the 3D modeling stage. Correction geometries and dimensional adaptations are calculated and integrated into the digital model before manufacturing, so that the final component achieves the desired precision without requiring post-processing finishing operations.
Solution Approach 2:
The patent utilizes parameter changes by systematically adjusting geometric parameters of the 3D model based on orientation, dimension, and configuration factors. Correction factors modify dimensions and correction geometries alter shapes to compensate for known SLM process deviations, transforming the model parameters to predictably achieve target dimensions after manufacturing.
2Manufacturing precision
If finishing operations are performed to improve manufacturing precision, then geometrical accuracy is improved, but device complexity and production time increase
Solution Approach 1:
The patent extracts the precision correction function from the post-manufacturing finishing stage and relocates it to the pre-manufacturing design stage. By calculating and applying correction geometries and dimensional adaptations during 3D modeling, the need for complex finishing operations is eliminated, simplifying the overall manufacturing process while maintaining high precision.
Solution Approach 2:
The patent performs preliminary action by pre-compensating for expected deformations and geometric inaccuracies during the 3D modeling stage. Correction geometries and dimensional adaptations are calculated and integrated into the digital model before manufacturing, so that the final component achieves the desired precision without requiring post-processing finishing operations.
3Manufacturing precision
If correction factors and geometries are applied as a function of orientation, dimension and configuration, then manufacturing precision is improved, but calculation complexity increases
Solution Approach 1:
The patent applies local quality by implementing orientation-dependent, dimension-dependent, and configuration-dependent correction factors and geometries. Different regions of the component receive tailored corrections based on their specific characteristics: overhangs are compensated with orientation-specific adjustments, small features receive dimension-appropriate scaling, and complex configurations get configuration-adapted correction geometries.
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
Enables the production of components with precise geometrical accuracy, including undercuts and internal flow channels, without additional finishing, enhancing the range of applications and reducing production costs, particularly for gas turbine components.
Implementation Method 1
In a selective laser melting method, powdered material is used, from which an object is produced stepwise by means of a laser.
Data Source
AI summary
An adaptation method for a modelling method in which, by means of target geometry, model geometry, which is derived from the target geometry, is created for an object to be produced by a selective laser melting method is provided. In the adaptation method, adapted model geometry is produced from the derived model geometry by dimension adaptation by means of a correction factor and/or by geometry adaptation by means of correction geometry.