Variable Build Plates for Multi-Height Additive Manufacturing
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Solution Overview
Problem
Traditional additive manufacturing systems require machining parts to similar dimensions before processing, limiting their ability to accommodate dimensional differences during repair or restoration of complex components like turbine blades, which can lead to inefficiencies and additional rework.
Innovation Solution
The use of variable build plates with adjustable features, such as telescopic shafts and multi-axis robotic actuation, allows for positioning and orientation adjustments of parts at different heights and orientations within the build chamber, enabling precise alignment and layering without the need for prior machining, using a control system to fuse material from a powder supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional additive manufacturing systems process multiple parts in batch, then productivity is improved, but manufacturing precision deteriorates due to requiring all parts to be machined to similar dimensions first
Solution Approach 1:
The build plate is made dynamically adjustable with telescopic shafts and actuators that allow real-time repositioning during the additive manufacturing process. This enables the system to adapt to parts with different initial dimensions while maintaining precise layer-by-layer construction, resolving the contradiction between batch processing capability and dimensional accuracy
Solution Approach 2:
The system changes the positional parameters of the build plate relative to the laser source and powder bed. By adjusting the build plate position dynamically, parts with varying dimensions can be processed together in batch while each part maintains its required manufacturing precision through compensated positioning
2Ease of manufacture
If parts are machined to lowest common dimension for batch processing, then ease of manufacture is improved, but loss of substance increases due to material removal
Solution Approach 1:
The system performs preliminary positioning of parts on the build plate before additive manufacturing begins. The telescopic build plate is pre-adjusted to accommodate the dimensional variations of different parts, eliminating the need for preliminary machining to lowest common dimension and preventing material waste
Solution Approach 2:
The adjustable build plate acts as an intermediary between parts of different dimensions and the fixed laser/powder bed system. It mediates the dimensional differences by providing individual positioning for each part, avoiding the need to machine all parts to uniform dimensions and thus preventing material loss
3Manufacturing precision
If single part processing is used for repair operations, then manufacturing precision is maintained, but productivity deteriorates
Solution Approach 1:
The build plate is segmented into multiple independently adjustable sections, each capable of holding and positioning a different part. This segmentation allows multiple parts to be processed simultaneously in batch while each section maintains the precise positioning required for accurate repair operations, resolving the contradiction between repair accuracy and processing speed
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 enables efficient repair and restoration of complex components by accommodating dimensional variations, reducing rework and allowing for uniform layering across parts, thereby improving the additive manufacturing process for complex geometries and batch processing of multiple parts.
Implementation Method 1
The principle behind additive manufacturing processes involves the selective melting of atomized precursor powder beds by a directed energy source, producing the lithographic build-up of the workpiece, layer-by-layer. The melting of the powder occurs in a small localized region of the energy beam, producing small volumes of melting, called melt pools, followed by rapid solidification
Implementation Method 2
The two or more variable build plates are configurable to position two or more parts at different heights relative to a top level of the build chamber
Implementation Method 3
adjustment of the at least one of the two or more variable build plates can include aligning a build region of the two or more parts level with respect to the top level of the build chamber
Data Source
AI summary
Disclosed herein is an additive manufacturing system that includes an energy source, a powder supply, and a build chamber. The build chamber includes a base plate and two or more variable build plates coupled to the base plate. The two or more variable build plates each have one or more adjustable features. The two or more variable build plates are configurable to position two or more parts at different heights relative to a top level of the build chamber. The additive manufacturing system also includes a control system configured to control the energy source to fuse material from the powder supply to at least one of the two or more parts while the two or more parts are respectively positioned by the two or more variable build plates at different heights relative to the top level of the build chamber.