Impeller and method using solid free form fabrication
View Patent ↗The present invention relates to the use of solid freeform fabrication (SFF) technology in the manufacture of impeller blades. The impeller blades may be metal plated and further incorporated onto a rigid skeletal frame to allow for more desirable wear resistance and strength.
1. A method for manufacturing an impeller blade, comprising:
modeling a desired shape of the impeller blade using computer aided design (CAD);
fabricating the desired shape of the impeller blade using a solid free form manufacturing (SSF) technique; and
metal-plating the exterior surface.
2. The method according to claim 1 , wherein the impeller blade has an interior space and an exterior surface.
3. The method according to claim 2 , further comprising the step of inserting a skeletal support structure into the interior space.
4. The method according to claim 2 , wherein said step of metal-plating comprises electrolessly plating the exterior surface.
5. The method according to claim 4 , wherein the step of metal-plating further comprises of electrolytically plating the exterior surface.
6. The method according to claim 4 , wherein the exterior surface is electrolessly plated with copper.
7. The method according to claim 5 , wherein the exterior surface is electrolytically plated with nickel.
8. The method according to claim 1 , wherein said step of fabricating comprises:
fabricating a first impeller segment having an exterior surface, using computer aided design (CAD); and
fabricating a second impeller segment having an exterior surface, using computer aided design (CAD).
9. The method according to claim 8 , further comprising:
mating the first impeller segment onto a rigid skeleton;
mating the second impeller segment onto the rigid skeleton; and
fastening the first impeller segment and the second impeller half to each other.
10. The method according to claim 9 , wherein said step of fastening is chemical bonding.
11. The method according to claim 9 , wherein said step of fastening is mechanical fastening.
12. The method according to claim 3 , wherein the skeletal support structure is metal.
13. The method according to claim 12 , wherein the skeletal support structure comprises a plurality of metal rods and a hub having a proximal end and a distal end, wherein the metal rods extend axially from proximal end to the distal end.
14. The method according to claim 1 , wherein the solid free form manufacturing (SSF) technique is three dimensional printing (3DP).
15. The method according to claim 1 , wherein the solid free form manufacturing (SSF) technique is stereo-lithography (SLA).
16. The method according to claim 1 , wherein the solid free form manufacturing (SSF) technique is selective laser sintering (SLS).
17. The method according to claim 1 , wherein the solid free form manufacturing (SSF) technique is ballistic particle manufacturing (BPM).
18. The method according to claim 1 , wherein the solid free form manufacturing (SSF) technique is fusion deposition modeling (FDM).
19. An impeller, comprising:
means for modeling a desired shape of the impeller blade having an interior space and an exterior surface, using computer aided design (CAD);
means for fabricating the desired shape of the impeller blade using a solid free form manufacturing (SSF) technique;
means for metal-plating the exterior surface; and
a skeletal support means disposed within the interior space.
20. The impeller according to claim 19 , further comprising a means for electrolessly plating the exterior surface with copper.
21. The impeller according to claim 19 , further comprising a means for electrolytically plating the exterior surface with nickel.