Tilted Pump Case Additive Manufacturing Without Supports
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Solution Overview
Problem
Existing fuel pumps for aircraft are difficult to manufacture additively due to traditional manufacturing methods, making them uneconomical and limiting the application of additive manufacturing techniques.
Innovation Solution
A method for additively manufacturing a fluid pump case in a tilted orientation without internal non-build plate support structures, except for coincidental support in specific locations, and post-process milling to achieve the final shape and finish, utilizing a Cartesian build and part coordinate system with defined tilt angles and coincidental support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional molding and machining methods are used to manufacture fuel pumps, then manufacturing precision and reliability are maintained, but manufacturing complexity increases and additive manufacturing becomes uneconomical
Solution Approach 1:
The patent changes the build orientation parameter by tilting the fuel pump case at approximately 45 degrees relative to the build plate. This parameter change allows the internal apertures to be formed without requiring non-coincidental support structure, making additive manufacturing economical and feasible while maintaining manufacturing precision
Solution Approach 2:
The patent introduces a tilted orientation dimension to the build process. By orienting the pump case at an angle rather than building it in the conventional horizontal position, the internal geometries can be created directly during additive manufacturing without requiring additional support structures or post-processing operations
2Ease of manufacture
If additive manufacturing is attempted with conventional orientations, then manufacturing simplicity increases, but support structure must be added in internal apertures increasing device complexity and post-processing requirements
Solution Approach 1:
The patent changes the build orientation parameter to approximately 45 degrees, which eliminates the need for non-coincidental support structure in internal apertures. This single parameter change simplifies the additive manufacturing process while reducing device complexity by removing unnecessary support structures
Solution Approach 2:
The patent extracts or removes the requirement for non-coincidental support structure from the internal apertures. By tilting the build orientation, the internal geometries become self-supporting during fabrication, eliminating the need to add and subsequently remove support structures
3Productivity
If internal apertures are manufactured without support structure, then post-processing requirements are reduced, but manufacturing precision may be compromised
Solution Approach 1:
The patent changes the build orientation parameter to approximately 45 degrees, which allows internal apertures to be manufactured without support structure while maintaining manufacturing precision. The tilted orientation provides adequate support during layer deposition without requiring additional support structures that would need post-processing removal
Data Source
AI summary
In accordance with at least one aspect of this disclosure, embodiments of fluid pumps, pump cases, valve bodies, and volutes are disclosed herein. Embodiments of methods for manufacturing fluid pumps, pump cases, valve bodies, and volutes are also disclosed herein. Embodiments can include additive manufacturing, for example. Certain embodiments can include additively manufacturing a pump case in a tilted orientation, utilizing only coincidental support structure having a unique shape, and with teardrop shaped volute and/or valve body.