Test Bar Identification via Indentation Pattern in SLS Builds
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Solution Overview
Problem
Existing selective laser sintering methods face issues with identifying test coupons, as recessed numbers create stress concentrations leading to failure during tensile testing, and methods like using tabs increase build time and reduce recyclable powder, resulting in unusable builds and significant costs.
Innovation Solution
A system and method for identifying test bars using a pattern of indentations on the grip sections, which are arranged in a readable format, providing unique digital information without interfering with material testing, ensuring compliance with ASTM D638 standards and maximizing recyclable powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If recessed numbers are formed on test coupons for identification, then identification is provided, but stress concentrations occur leading to failure during tensile testing
Solution Approach 1:
The patent uses optical marking (printing) to create identification on test coupons instead of forming recessed features. This copying approach provides identification without creating physical stress concentration points that would compromise the structural integrity of the test specimens during tensile testing.
2Loss of information
If tabs with printed numbers are used for identification, then identification is provided, but build time increases and recyclable powder decreases
Solution Approach 1:
The patent extracts the identification function from separate physical structures (tabs) and integrates it directly into the test coupon design through optical marking. This eliminates the need for additional tabs, thereby reducing build time and maximizing the amount of recyclable powder available from each build.
3Loss of information
If recessed numbers are formed on test coupons, then identification is provided, but the numbers create areas of stress concentration
Solution Approach 1:
The patent replaces the mechanical method of forming recessed numbers (which create stress concentrations) with an optical marking system. This substitution provides identification without compromising the mechanical strength of the grip sections, ensuring that test specimens can withstand tensile loading without failure at the marked locations.
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
The indentation pattern effectively identifies test bars without causing stress concentrations, reducing failure rates and maintaining the integrity of the test specimens, thus ensuring efficient and cost-effective builds by maximizing the use of recyclable powder.
Implementation Method 1
Selective laser sintering ('SLS') is an additive manufacturing technique that uses a laser to fuse small particles of plastic, metal (direct metal laser sintering), ceramic, or glass powders into a mass having a desired three-dimensional (3-D) shape
Implementation Method 2
The laser selectively fuses the powder material by scanning cross-sectional layers generated from a 3-D digital description of the desired object onto the top layer of a bed of the powder material
Data Source
AI summary
A system and method for identifying test bars formed during a selective laser sintering build. A part cake is formed during a selective laser sintering build. The part cake comprises parts formed from a powder by selective laser sintering and unsintered powder around the formed parts. The parts include test bars for performing material testing. Each test bar includes a plurality of indentations in a first grip section and a second grip section. The plurality of indentations are arranged in a information providing pattern that is adapted to be readable after the test part is removed from the part cake.