Wire Additive Manufacturing With Granular Media Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Metal additive manufacturing, particularly wire additive manufacturing, faces challenges in minimizing component deformation during the manufacturing process, often requiring a build plate to absorb stresses, which can lead to residual deformation and necessitate substantial post-processing.
Innovation Solution
A wire additive manufacturing machine with a sensor and control system that measures the distance between the torch and the material layer, allowing for real-time adjustments to maintain optimal manufacturing conditions, and uses a granular media with an anchor to support the component, enabling it to deform freely during printing, reducing the need for a build plate and minimizing post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a build plate is used to minimize component deformation during manufacturing, then component stability is improved, but residual deformation increases and post-processing requirements increase
Solution Approach 1:
The patent removes the build plate from the manufacturing system entirely, replacing it with granular media that allows components to deform naturally during printing. This extraction of the build plate eliminates the source of residual deformation while maintaining component support through the granular media and anchor mechanism.
Solution Approach 2:
The patent changes the support medium from a rigid build plate to granular media with different mechanical properties. The granular media allows for natural deformation by providing flexible support that can accommodate stress-induced shape changes without imposing rigid constraints that cause residual deformation.
2Manufacturing precision
If real-time sensor feedback and control system adjustments are implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a sensor coupled to the housing via a support that continuously measures the distance between the torch and the layer of material. The control system receives this feedback data and automatically adjusts torch position to maintain optimal manufacturing conditions, creating a closed-loop control system that improves precision through real-time monitoring and adjustment.
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 allows for the production of components with reduced residual stress and improved properties by enabling natural deformation during manufacturing, resulting in parts that meet dimensional tolerances without the need for extensive post-processing.
Implementation Method 1
The torch provides energy to melt the material employing any of a number of energy sources
Implementation Method 2
The sensor is configured to measure a first data, where the first data is a distance between the torch and a layer of material
Implementation Method 3
The media is positioned beneath the nozzle and expanded over a print area
Data Source
AI summary
A metal additive manufacturing machine includes a housing, a torch at least partially disposed within the housing, a media, a material, a sensor, and a control system. The media is granular and substantially similar to the material such that it can initiate and maintain an arc, if necessary, and be incorporated into the component. The media forms a flat or topographically featured structure. The material is positioned such that it is melted by the torch and forms a layer of material onto the media. The sensor is configured to measure a first data, where the first data is a distance between the torch and a layer of material. The control system is operably coupled to the sensor and configured to receive the first data and compare the first data to a first data threshold. The control system sends a command to move the torch in a z-direction.