Vertical Cooling Structures for Additive Manufacturing Thermal Control
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Solution Overview
Problem
Controlling heating and cooling during additive manufacturing of metal components is challenging, leading to stress, warping, and changes in material characteristics, as conventional methods struggle to effectively manage temperature fluctuations within the manufacturing process.
Innovation Solution
The implementation of a system with vertical cooling structures integrated into the build plate and build chamber, which retract from the powder bed to cool components through unfused powdered materials, combined with a temperature control system that independently manages the build plate and cooling structures, allowing precise temperature control during the additive manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods (build plate cooling or air cooling) are used, then cooling capability is provided, but temperature control precision is insufficient leading to stress and warping
Solution Approach 1:
The cooling system is segmented into multiple independent vertical cooling structures that can be individually controlled. Each cooling structure can be positioned at different locations and controlled at different temperature levels, allowing precise localized temperature management to prevent warping and stress in specific component regions.
Solution Approach 2:
The invention transitions from conventional planar cooling (build plate cooling) to three-dimensional cooling by introducing vertical cooling structures that extend upward from the build plate. This adds a vertical dimension to heat dissipation, enabling more effective and uniform temperature control throughout the component volume.
2Temperature
If vertical cooling structures are introduced, then cooling effectiveness is improved, but device complexity increases
Solution Approach 1:
The vertical cooling structures serve multiple functions: they provide cooling through unfused powder, act as thermal shields to protect underlying powder from excessive heat, and can be independently controlled to address different thermal requirements. This multi-functionality reduces the need for separate cooling and shielding systems.
Solution Approach 2:
The unfused powdered material serves as an intermediary medium that transfers heat from the component to the vertical cooling structures. The powder bed acts as a thermal conduit, enabling efficient heat removal while simplifying the cooling structure design compared to direct contact cooling systems.
3Temperature
If independent temperature control of cooling structures is implemented, then temperature management precision is improved, but control system complexity increases
Solution Approach 1:
The control system dynamically adjusts the temperature of each vertical cooling structure based on real-time monitoring of component temperature and thermal requirements. The system can adapt cooling rates and temperatures during different stages of the additive manufacturing process, enabling precise temperature management while maintaining operational flexibility.
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 solution effectively mitigates thermal stress and warping by providing controlled cooling, maintaining material characteristics and improving the overall quality of the additive manufacturing process.
Implementation Method 1
The at least one vertical cooling structure cools at least a portion of the component through unfused powdered materials between the at least one vertical cooling structure and the component
Data Source
AI summary
This disclosure provides systems and tooling for cooling components during additive manufacturing. A build plate supports layers of powdered materials as they are positioned and selectively fused to create the component. The build plate defines a build surface and the build surface retracts in a working direction opposite a build direction for the component. At least one vertical cooling structure is provided perpendicular to the build plate and protruding from the build plate as the build surface retracts. The vertical cooling structure cools at least a portion of the component through unfused powdered materials between the vertical cooling structure and the component.