Tip Structure Additive Build Alignment on Pre-Existing Parts
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Solution Overview
Problem
In hybrid additive manufacturing, accurately aligning the manufacturing setup with the top surface of a pre-existing part is challenging due to tolerance stacking effects and requires complex machining operations, leading to insufficient accuracy.
Innovation Solution
A method involving an aligning plate that is engraved with the top contour of the part using an energy beam, allowing for precise alignment of the part's surface with the engraved contour, enabling accurate additive manufacturing of the tip structure without the need for optical recognition systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical recognition systems are used to align the manufacturing setup with the pre-existing part, then alignment can be performed, but accuracy is insufficient due to tolerance stacking effects and requires complex machining operations
Solution Approach 1:
The patent creates a digital copy (3D scan) of the pre-existing part's actual geometry and uses this digital model to generate the machining program. This eliminates the need for complex optical recognition systems and manual alignment procedures, as the digital twin accurately represents the part's true dimensions and features, directly resolving the alignment accuracy issue while simplifying the overall process.
Solution Approach 2:
The patent replaces complex mechanical alignment procedures and optical recognition systems with a digital scanning and modeling approach. The 3D scanner captures geometric data, which is then processed into a digital model that directly drives the machining operations, substituting mechanical complexity with digital precision.
2Manufacturing precision
If conventional alignment methods with mounting dowels are used, then the setup can be calibrated, but accuracy is insufficient due to tolerance stacking effects
Solution Approach 1:
Instead of relying on physical mounting dowels and manual calibration, the patent creates a digital copy of the part's actual geometry through 3D scanning. This digital model captures the true positions of all features, eliminating tolerance stacking effects that occur in physical alignment methods, while also simplifying the manufacturing process by removing complex dowel hole machining operations.
3Measurement precision
If complex machining operations are performed to achieve accurate alignment, then positional calibration can be attempted, but the process becomes extremely difficult and sophisticated
Solution Approach 1:
The patent performs 3D scanning and digital model creation before the machining operations begin. This preliminary action captures the part's actual geometry, allowing the machining program to be generated based on real measurements rather than theoretical dimensions. This eliminates the need for complex post-alignment calibration operations, as the digital model already contains all necessary positional information.
Solution Approach 2:
The digital 3D scan creates an accurate replica of the part's geometry, which is then used to generate the machining program. This digital copy eliminates the need for complex physical alignment and calibration operations, as all positional information is already captured in the digital model, significantly reducing manufacturing complexity.
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 method significantly improves alignment accuracy, simplifies the process, and allows for high-quality refurbishment of parts by enabling precise adaptation to any geometry, enhancing the flexibility and repeatability of the manufacturing process.
Implementation Method 1
engraving a mating or top contour or cross section of the part onto or in the aligning plate with an energy beam of the setup
Data Source
AI summary
A method for additively manufacturing a tip structure on a pre-existing part includes: a) placing the part in a build space of a beam-assisted additive manufacturing setup and below a transparent aligning plate, b) engraving a top contour of the part onto the aligning plate with an energy beam of the setup, c) aligning a top surface of the part such that the top surface coincides with the engraved contour, d) removing the aligning plate from the setup, and e) additively manufacturing the tip structure according to a predefined geometry on the top surface.