Coolant Supply Through Support Assembly for Stable AM Builds

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Additive manufacturing processes face challenges in controlling the temperature of build components, leading to issues with dimensional stability and microstructural properties, and traditional cooling methods introduce delays in the manufacturing process.

Innovation Solution

A manufacturing system with a coolant supply system that selectively supplies coolant to both additive manufacturing and milling assemblies, regulating the temperature of build components and milling tools through thermal communication and controlled coolant flow based on operational modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the build component temperature is allowed to increase to maintain manufacturing speed, then productivity is improved, but dimensional stability and microstructural properties deteriorate

Engineering Contradiction:

Improvemanufacturing speedVSAvoiddimensional stability

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

A coolant system is introduced as an intermediary between the energy source and the build component to regulate temperature. The coolant circulates through channels in the support assembly, absorbing excess heat from the build component without interrupting the additive manufacturing process, thus maintaining both high manufacturing speed and dimensional stability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The temperature parameter of the build component is actively controlled by adjusting coolant flow rate and temperature. By changing the coolant parameters (flow rate, temperature), the system can maintain the build component within optimal temperature ranges for both productivity and precision

Inventive Principle:

Principle #35Parameter changes

2Temperature

If the energy source is intermittently interrupted to regulate build component temperature, then temperature control is improved, but manufacturing productivity deteriorates due to process delays

Engineering Contradiction:

Improvebuild component temperature controlVSAvoidmanufacturing process continuity

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The coolant system enables continuous temperature regulation during the additive manufacturing process. The coolant continuously circulates through the support assembly, providing ongoing heat removal that allows the energy source to operate continuously without interruption, maintaining both temperature control and process continuity

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The coolant acts as a mediator that provides continuous passive cooling without requiring interruption of the energy source. This eliminates the need to stop manufacturing to cool the build component, thereby maintaining productivity while achieving temperature regulation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If a coolant system is introduced to regulate build component temperature, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvetemperature regulation accuracyVSAvoidcoolant supply system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The coolant channels are merged with the support assembly structure. The support assembly serves dual functions: supporting the build component and providing thermal management pathways. This integration reduces the number of separate components and simplifies the overall system while maintaining effective temperature regulation

Inventive Principle:

Principle #5Merging (Combining)

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 continuous formation of build components with desired geometrical and structural properties without delays, by effectively managing temperature fluctuations during the manufacturing process.

Implementation Method 1

The coolant supply system may be configured to remove heat from the support assembly as the first build component is manufactured by flowing the coolant through at least a portion of the support assembly to regulate a temperature of the build component

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11426942B2Manufacturing systems with coolant supply systems and related methods

Publication Date: 2022.08.30 THE BOEING CO

AI summary

Manufacturing systems with coolant supply systems and related methods. A manufacturing system includes an additive manufacturing (AM) assembly, a milling assembly, and a coolant supply system. The AM assembly includes a support assembly that supports a build component and that is in thermal communication with the build component. The coolant supply system is configured to remove heat from the support assembly by flowing the coolant through at least a portion of the support assembly. A method of operating a manufacturing system during a manufacturing process includes detecting a manufacturing mode of the manufacturing system, forming a build component via the manufacturing process, and, at least partially concurrent with the forming the build component, selectively supplying a coolant to a support assembly and/or a milling tool. The selectively supplying the coolant is based, at least in part, on the detecting the manufacturing mode.