Voxel Alignment in Non-Continuous Deposition to Reduce Excess Material
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Solution Overview
Problem
Current additive manufacturing processes, such as Laser Powder Bed Fusion, Electron Beam Melting, and Selective Laser Sintering, face limitations including small build volumes, low deposition rates, high costs, and complex toolpath generation, which hinder widespread adoption due to high equipment and material costs, as well as challenges in dynamic accuracy and surface finish.
Innovation Solution
A non-continuous deposition method that uses discrete increments of material deposited according to a digital model, with an array of voxel spaces to minimize excess material and optimize deposition efficiency, allowing for modular scalability and reduced costs by employing standard GMAW processes and robotic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If Laser Powder Bed Fusion, Electron Beam Melting, or Selective Laser Sintering processes are used, then manufacturing precision is improved, but build volume is limited and deposition rate is low
Solution Approach 1:
The patent segments the build space into an array of discrete voxel spaces, allowing independent deposition at each voxel location. This segmentation enables parallel processing and increases deposition rate while maintaining precision through controlled material placement at each voxel site.
Solution Approach 2:
The patent transitions from traditional layer-by-layer deposition to three-dimensional voxel-based deposition, adding spatial dimensionality to the deposition process. This allows simultaneous deposition at multiple locations throughout the build volume, dramatically increasing productivity while maintaining manufacturing precision through controlled voxel filling.
2Productivity
If high-power lasers and complex motion systems are used in DED, then deposition rate is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces expensive, complex high-power laser systems with more affordable arc welding processes and standard robotic motion systems. While individual deposition events may require adjustment, the overall system cost and complexity are reduced by using commercially available, less expensive components that achieve comparable deposition rates.
Solution Approach 2:
The patent changes the fundamental deposition parameters from laser-based high-energy density processing to arc-based deposition with controlled heat input. This parameter change allows using standard robotic systems instead of complex multi-axis CNC platforms, reducing device complexity while maintaining productivity through optimized deposition patterns.
3Manufacturing precision
If fine powder feedstock is used in DED, then manufacturing precision is improved, but material cost increases and powder loss reaches 10-50%
Solution Approach 1:
The patent changes the feedstock form from fine powder to wire or rod materials, fundamentally altering the material delivery mechanism. This parameter change eliminates powder loss associated with pneumatic conveying and selective deposition, as wire feedstock can be precisely fed and fully utilized in the deposition process.
Solution Approach 2:
The patent eliminates the need to discard unused fine powder by using wire feedstock that can be precisely controlled and fully utilized. Any excess material can be recovered and reused without the contamination and loss issues inherent in powder-based systems, significantly reducing material waste.
4Device complexity
If robotic systems with 6-axis welding robots are used in WAAM, then device complexity is reduced, but dynamic accuracy deteriorates increasing manufacturing defects
Solution Approach 1:
The patent segments the toolpath into discrete voxel deposition events rather than continuous motion. This segmentation allows the robotic system to operate at its lower dynamic accuracy while achieving high precision through controlled material placement at each voxel location, compensating for motion inaccuracies.
Solution Approach 2:
The patent performs preliminary planning of the voxel deposition sequence to optimize robotic motion paths and minimize dynamic errors. By pre-calculating the optimal deposition order and positioning, the system compensates for robotic dynamic inaccuracies before execution, maintaining manufacturing precision despite using simpler 6-axis systems.
5Productivity
If deposition rate is increased in WAAM, then productivity is improved, but surface finish deteriorates and residual stresses increase
Solution Approach 1:
The patent segments the deposition process into discrete voxel events with controlled timing and positioning. This segmentation allows high deposition rates through parallel processing while maintaining surface finish by controlling the placement and cooling of each voxel, preventing the heat accumulation that causes poor surface quality in continuous deposition.
Solution Approach 2:
The patent employs periodic deposition cycles at each voxel location, allowing controlled cooling intervals between deposition events. This periodic action manages heat input and residual stress accumulation while maintaining high overall productivity through efficient cycle timing and parallel voxel processing.
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 the production of larger parts at higher deposition rates with lower costs, improved surface finishes, and reduced residual stresses, while simplifying toolpath generation and operation, thereby increasing the accessibility and efficiency of additive manufacturing.
Implementation Method 1
utilizing standard arc welding processes such as Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW), and Plasma Arc Welding (PAW)
Implementation Method 2
Laser Powder Bed Fusion (LPBF)
Implementation Method 3
Electron Beam Melting (EBM)
Implementation Method 4
Selective Laser Sintering (SLS)
Data Source
AI summary
In the context of additive manufacturing processes wherein objects are built by layered accumulations of discrete instantaneous deposits of feedstock material at specific locations according to a three-dimensional digital data model, methods and systems are provided for selecting an advantageous alignment between an array of fillable voxel spaces and a model layer slice. In accordance with some embodiments, variable alignment achieves an overall reduction in the amount of excess material formed by discrete depositions of material and extending beyond the contours of the object.