Additive-Manufactured Valve Body Without Internal Support Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional fuel pump manufacturing methods and designs make it difficult to additively manufacture fuel pumps that are both economical and effective, as they require non-build plate support structures within internal apertures, which are costly and inefficient.
Innovation Solution
The method involves additively manufacturing a fluid pump case in a tilted orientation without non-build plate support structures, except for coincidental locations intended for post-processing milling, allowing for the elimination of support structures and enabling efficient production of fuel pumps with complex geometries like valve bodies and volute channels.
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 cost increases and production efficiency decreases
Solution Approach 1:
The patent changes the manufacturing method from traditional molding and machining to additive manufacturing, fundamentally altering the production parameters. This enables complex geometries to be manufactured directly without multiple processing steps, reducing both cost and lead time while maintaining acceptable precision through optimized build parameters and post-processing
Solution Approach 2:
The patent transitions from subtractive and formative manufacturing to additive manufacturing, adding a new dimensional approach to production. This enables the creation of complex internal geometries and optimized structures that cannot be achieved through traditional molding and machining, directly addressing the cost and efficiency concerns
2Ease of manufacture
If non-build plate support structures are used in internal apertures during additive manufacturing, then structural support is provided, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the need for non-build plate support structures within internal apertures by carefully designing the build orientation and utilizing coincidental support only where already intended for post-process milling. This removes the complexity and cost associated with designing, manufacturing, and removing temporary support structures from the additive manufacturing process
Solution Approach 2:
Instead of adding support structures to enable manufacturing, the patent inverts the approach by designing the part and selecting build orientations that eliminate the need for internal support structures entirely. The manufacturing process is adapted to work without supports, rather than using supports to enable the manufacturing of complex geometries
3Adaptability or versatility
If additive manufacturing is used to produce complex geometries, then design flexibility and weight are improved, but manufacturing precision and surface finish deteriorate
Solution Approach 1:
The patent applies preliminary action by performing selective post-process milling on specific surfaces and features after additive manufacturing. This preliminary identification and targeted processing of critical surfaces ensures that design flexibility and weight benefits of additive manufacturing are maintained while achieving the required surface finish and dimensional precision on mating surfaces
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 approach reduces manufacturing costs, maintains or improves performance, and eliminates the need for additional post-processing steps, resulting in fuel pumps that are cost-effective and comparable in weight and performance to traditionally casted parts.
Implementation Method 1
additively manufacturing a fluid pump case in a tilted orientation without any non-build plate support structure in any internal apertures of the fluid pump case
Data Source
Figure 1A
Figure 1B
Figure 1C
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.