Method of generating support structure of tube components to become functional features

Patent metadata

Field	Value
Publication number	US-10502500-B2
Application number	US-201715804257-A
Country	US
Kind code	B2
Filing date	Nov 6, 2017
Priority date	Sep 23, 2013
Publication date	Dec 10, 2019
Grant date	Dec 10, 2019

Abstract

A method includes building a tubular object by a layer-by-layer additive manufacturing process. A structure integrally connected to the tubular object for supporting a portion of the tubular object is formed during building of the tubular object. The structure provides vibration dampening, heat shielding, heat transfer, stiffening, energy absorption, or mounting after the tubular object is built.

First claim

The invention claimed is:

1. A method comprising:
building a tubular object designed for and built by a layer-by-layer additive manufacturing process;
forming, while building the tubular object, a structure integrally connected to the tubular object for supporting a portion of the tubular object having a build direction that exceeds a build limit angle of the layer-by-layer additive manufacturing process during building of the tubular object with the layer-by-layer additive manufacturing process, and wherein the structure provides vibration dampening, heat shielding, heat transfer, stiffening, energy absorption, or mounting after the tubular object is built.

2. The method of claim 1 , wherein a portion of the structure comprises a heat-shield structure, mounting structure, honeycomb structure, fin structure, matrix structure, lattice structure, rib structure, filter structure, bushing structure, or slot.

3. The method of claim 1 , wherein the tubular object includes at least one channel therein extending for the length of the tubular object, and the at least one channel is configured to allow transport of a fluid through the tubular object.

4. The method of claim 3 , wherein the structure is disposed within the tubular object and the structure is configured to allow transport of the fluid through the tubular object.

5. The method of claim 3 , wherein the fluid comprises oil, fuel, gas, or air.

6. The method of claim 1 , wherein the tubular object comprises a tube designed for use in a gas turbine engine.

7. A method comprising:
designing a component having a tubular body and a structure that performs at least one of vibration dampening, heat shielding, heat transfer, stiffening, energy absorption, or mounting, wherein the structure is positioned with respect to the tubular body so that the structure will act as a support to the component during layer-by-layer additive manufacturing of the component;
creating digital files defining the component on a layer-by-layer basis; and
producing the component by layer-by-layer additive manufacturing using the digital files, wherein the structure supports the component during the producing of the tubular body, wherein a build direction of a portion of the tubular body exceeds a build limit angle of the layer-by-layer additive manufacturing process.

8. The method of claim 6 , wherein a portion of the structure comprises a heat-shield structure, mounting structure, honeycomb structure, fin structure, matrix structure, lattice structure, rib structure, filter structure, bushing structure, or slot.

9. The method of claim 7 , wherein the tubular object includes at least one channel therein extending for the length of the tubular object, and the at least one channel is configured to allow transport of a fluid through the tubular object.

10. The method of claim 9 , wherein the structure is disposed within the tubular object and the structure is configured to allow transport of the fluid through the tubular object.

11. The method of claim 9 , wherein the fluid comprises oil, fuel, gas, or air.

12. The method of claim 7 , wherein the tubular object comprises a tube designed for use in a gas turbine engine.

13. The method of claim 1 , wherein the build limit angle of the layer-by-layer additive manufacturing process comprises approximately 45 degrees off vertical.

14. The method of claim 7 , wherein the build limit angle of the layer-by-layer additive manufacturing process comprises approximately 45 degrees off vertical.

Assignees

• United Technologies Corp

Inventors

• Butcher Evan
• Twelves Jr Wendell V
• Schirtzinger Gary A
• Ott Joseph
• Kironn Lexia

Classifications

• B29C64/106

  using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• F16L9/19

  Multi-channel pipes or pipe assemblies · CPC title

• F28F2255/00

  Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title