Powder evacuation device for a support structure used in additive manufacturing of a part by laser powder bed fusion

Abstract

Powder evacuation device for a support structure for additive manufacturing of a part by laser powder bed fusion, comprising: a plurality of pillars (11), each pillar (11) comprising a body (14) having a first end (15) forming a base and a second end (16) for connecting the evacuation device to the support (3) opposite the first end (15), and a void (12) for the evacuation of unfused powder provided between the pillars (11). Figure for the abbreviation: Fig 3

Description

Title of the invention: Device for removing powder from a support for additive manufacturing of a part by laser fusion on a powder bed Technical field

[0001] The present invention relates to the manufacture of parts, in particular metal parts, by additive manufacturing and, more particularly, the manufacture of parts by laser fusion on a powder bed.

[0002] More specifically, the invention relates to a device for removing powder from a support for additive manufacturing of a part by laser powder bed fusion, a support assembly comprising a support and such a removal device, a method for manufacturing a part by laser powder bed fusion based on the use of such a support assembly, as well as an intermediate product obtained in the context of such a method. Previous techniques

[0003] An existing method for manufacturing a metal part by additive manufacturing is the laser powder bed fusion process, more commonly known as the "LBM process", from the English abbreviation Laser Beam Melting. The LBM process consists of the selective consolidation of layers of metal powder in the air of a laser in order to constitute, slice by slice, a three-dimensional object. It can also be used for shaping polymers.

[0004] Manufacturing by the LBM process is computer-controlled. A digital file groups together all the laser trajectory instructions layer by layer allowing the production of the part.

[0005] A manufacturing plate serves as a base for manufacturing the part and a powder spreading device allows the spreading of a layer of powder of the desired material on the manufacturing plate with a desired thickness. This device can be a roller or a scraper which moves in translation on an axis on either side of the powder bed.

[0006] When the powder layer is deposited, one or more laser(s) selectively scan(s) certain areas of the powder bed, corresponding to a slice of the part to be produced. The scanning pattern as well as all the laser parameters, such as the laser power, the scanning speed, the spacing between two laser passes, etc. are dictated by the digital file.

[0007] Passing the laser over the powder bed raises the powder to a temperature above its melting temperature. A molten bath is thus created. In re As it cools, this bath consolidates and forms a solid metal bead. After laser scanning a layer of powder, a two-dimensional section of the desired part is obtained.

[0008] As the build plate descends, the powder spreading device deposits a new layer of powder on top of the previous one. A new laser scan is carried out in order to consolidate a new section of the part.

[0009] Thus, iteratively, a three-dimensional part is reconstituted by successive consolidation of two-dimensional sections.

[0010] Due to their architecture, areas of certain parts need to be maintained during their manufacture by the LBM process so that they do not collapse. Indeed, during the melting of these areas, the unconsolidated powder of the previous layers is not sufficient to ensure this maintenance.

[0011] It is known to generate, simultaneously with the manufacture of the part, a structure manufactured in one piece with the part, and providing support for these particular areas.

[0012] In particular, there are supports having a honeycomb structure formed by a plurality of side walls which intersect to form the cells.

[0013] As the part and support are manufactured, powder accumulates in the cells.

[0014] When the supports have a large volume and the number of parts to be manufactured is high, the supports can trap a significant amount of unfused powder.

[0015] After manufacturing, the part is subjected to heat treatment, before being separated from the support.

[0016] This heating causes the sintering of the unfused powder trapped in the cells of the support, which then adheres firmly to the walls. This results in a more complex decoupling operation, with a support that is more difficult to remove from the part.

[0017] In addition, the powder hardened by sintering cannot be recycled and reused for the manufacture of new parts by additive manufacturing.

[0018] The powder must therefore be removed from the support, preferably before the assembly formed by the part, the support and the manufacturing plate is transferred out of the chamber in which the manufacturing takes place.

[0019] It is known to manufacture a support whose side walls forming the alveolar structure as well as the external walls which laterally delimit the support are fragmented, revealing a series of openings, such as slots. These openings allow the powder to be evacuated to the outside.

[0020] However, such a support is less robust than a support without fragmentation, and is not compatible with all types of scrapers. Statement of the invention

[0021] The present invention therefore aims to overcome the aforementioned drawbacks and to provide a device making it possible to facilitate the evacuation of the unfused powder trapped in the support upon completion of the manufacture of a part by additive manufacturing by powder bed fusion.

[0022] The present invention relates to a device for removing powder from a support for additive manufacturing of a part by laser fusion on a powder bed, comprising:

[0023] a plurality of pillars, each pillar comprising a body having a first end forming a base and a second end for connecting the evacuation device to the support opposite the first end, and

[0024] an empty space intended for the evacuation of unfused powder provided between the pillars.

[0025] Preferably, the dimensions of the body of the pillars decrease from the second end towards the first end.

[0026] According to one feature, the body may comprise at least three fins each extending from the base to the second end.

[0027] In one embodiment, the second end may be cruciform, the body comprising four fins each extending from the base towards one of the four branches forming the second cruciform end, preferably the base of the pillars being circular.

[0028] Preferably, each of the four branches forming the second cruciform end of one of the pillars is extended by one of the four branches forming the second cruciform end of an adjacent pillar.

[0029] In another embodiment, the second end may be formed by a star having three branches, the body comprising three fins each extending from the base towards one of the three branches forming the second end, preferably the base of the pillars being circular.

[0030] Preferably, each of the three branches forming the second star-shaped end of one of the pillars is extended by one of the three branches forming the second end of an adjacent pillar.

[0031] The invention also relates to a support assembly for additive manufacturing of a part by laser fusion on a powder bed, comprising:

[0032] a support having a honeycomb structure comprising a plurality of side walls forming honeycombs, the support comprising a first surface for supporting the part and a second surface opposite the first surface, and

[0033] an evacuation device as before, the second end of the pillars being connected to the second surface of the support,

[0034] the evacuation device and the support being monobloc.

[0035] Advantageously, each cell of the cell structure of the support may be bordered by at least three of the plurality of pillars.

[0036] Advantageously, the support may comprise external walls laterally delimiting the alveolar structure.

[0037] Preferably, said side walls forming the cells extend from a first portion of the support comprising the first surface for supporting the part to a second portion of the support comprising the second surface, the first portion comprising a number of side walls greater than the number of side walls of the second portion so that the size of at least a portion of the cells of the first portion according to a cross section perpendicular to the longitudinal axis of the cells is smaller than the size of the cells of the second portion.

[0038] Advantageously, the alveolar structure of the support may further comprise one or more intermediate portions positioned between said first and second portions, the number of side walls decreasing from the first portion to the second portion so that the size of the cells of each of the portions increases from the first portion to the second portion.

[0039] In one embodiment, the cross-section of the honeycomb structure of the support may comprise a right-angled pattern in which all or part of the side walls intersect at right angles.

[0040] In another embodiment, the cross-section of the honeycomb structure of the support comprises a honeycomb pattern.

[0041] The invention also relates to an intermediate product for additive manufacturing of a part by laser fusion on a powder bed, comprising a support assembly as described previously and the part, the support assembly and the part being in one piece.

[0042] The invention also relates to a method of manufacturing a part by laser fusion on a powder bed comprising:

[0043] the formation of the part by layer-by-layer fusion of a powder using a laser and, simultaneously with the formation of the part:

[0044] forming a support assembly as previously described.

[0045] Preferably, forming the support assembly and the part by layer fusion by layer of powder using a laser is carried out on a manufacturing plate.

[0046] Preferably, the support assembly, the part and the manufacturing plate being in one piece.

[0047] Advantageously, the manufacturing method may comprise the separation of the part obtained from the support assembly.

[0048] According to one characteristic, the decoupling can be carried out by machining, electroerosion and / or manual adjustment. Brief description of the drawings

[0049] The present invention will be better understood and other aims, advantages and characteristics will emerge from the detailed description which follows, comprising embodiments given purely for illustrative purposes and made with reference to the appended drawings, presented as non-limiting examples, which may serve to complete the understanding of the invention and the description of its implementation and, where appropriate, contribute to its definition, in which:

[0050] [Fig-1] is a schematic view of a part and a support manufactured by laser powder bed fusion according to an embodiment of the invention.

[0051] [Fig.2] represents a pattern of the alveolar structure of a support according to a mode of realization of the invention.

[0052] [Fig.3] is a detailed view of a powder discharge device according to a first embodiment of the invention.

[0053] [Fig.4] is a detailed view of a powder discharge device according to a second embodiment of the invention.

[0054] [Fig.5] is a schematic view of a part and a support manufactured by laser powder bed fusion according to another embodiment of the invention.

[0055] [Fig.6] illustrates the alveolar structure of a support according to another embodiment of the invention.

[0056] [Fig.7] represents the pattern of the intermediate portion of the support illustrated in [Fig.6].

[0057] [Fig.8] represents the pattern of the second portion of the support illustrated in [Fig.6].

[0058] [Fig.9] illustrates a pattern of a honeycomb structure of a support according to another mode of carrying out the invention.

[0059] [Fig. 10] illustrates a pattern of a honeycomb structure of a support according to another embodiment of the invention.

[0060] [Fig. 11] illustrates a pattern of a honeycomb structure of a support according to another embodiment of the invention.

[0061] It should be noted that, in the figures, the structural and / or functional elements common to the different embodiments may have the same references. Thus, unless otherwise stated, such elements have identical structural, dimensional and material properties.

[0062] In the description of the invention which will be made, the expression "at least one" used must be considered as equivalent to the expression "one or more".

[0063] It is specified that the expression “between” used in the present description of the invention must be understood as including each of the limits mentioned. Detailed description of at least one embodiment

[0064] [Fig.l] illustrates a metal part 1 manufactured by a powder bed laser fusion manufacturing method according to one embodiment of the invention.

[0065] The manufacturing method comprises forming the part 1 by layer-by-layer melting of a metal powder. A manufacturing plate 2 serves as a base for manufacturing the part 1.

[0066] Simultaneously with the formation of the part 1, the manufacturing method comprises the formation by laser fusion on a powder bed of a support 3 intended to support the part during its manufacture.

[0067] Advantageously, a powder spreading device allows the spreading of a layer of metal powder on the manufacturing plate 2. The spreading device may be a roller or a scraper which moves in translation from one end to another of the manufacturing plate 2.

[0068] When the powder layer is deposited, a laser selectively scans certain areas of the powder bed, corresponding to a slice of the part 1 and the support 3 to be produced.

[0069] Passing the laser over the bed of metal powder allows the latter to be raised to a temperature above its melting temperature. A molten bath is thus created. As it cools, this bath consolidates and forms a solid metal bead. At the end of the laser scanning of a layer of powder, a two-dimensional section of the desired part 1 and support 3 is therefore obtained.

[0070] The layer of powder deposited makes it possible to form both the part 1 and the support 3.

[0071] As the manufacturing tray 2 descends, the spreading device powder deposits a new layer of powder on top of the previous one. A new laser scan is carried out in order to consolidate a new slice of part 1 and support 3.

[0072] The part 1 and the support 3 in three dimensions are thus formed by successive consolidation of sections in two dimensions.

[0073] The support 3, the part 1 and the manufacturing plate 2 form a single-piece assembly.

[0074] Alternatively, the part 1 and the support 3 manufactured by the manufacturing method according to the invention may be made of a material other than metal, such as a polymer material, for example a composite polymer material.

[0075] The support 3 has a honeycomb structure. The honeycomb structure comprises a plurality of side walls 3' forming cells.

[0076] The side walls extend in the direction of the manufacturing plate 2, perpendicular to the plane passing through the manufacturing plate 2. In this way, the longitudinal axis of each cell extends perpendicular to the plane passing through the manufacturing plate 2.

[0077] The side walls of the honeycomb structure of the support 3 make it possible to support the part 1 during manufacturing.

[0078] In the illustrated example, the side walls 3' of the support 3 are arranged so as to form a pattern 8, visible along a cross-section of the support 3, according to which the side walls 3' intersect to form right angles, like a grid.

[0079] The cells form channels in which the unfused powder of each layer remains.

[0080] Furthermore, a powder evacuation device 13 is positioned under the support 3, advantageously between the support 3 and the manufacturing plate 2.

[0081] The support 3, the evacuation device 13 and the part 1 formed as well as the manufacturing plate 2 form a single-piece intermediate product.

[0082] With reference to [Fig.3] representing a first embodiment, the evacuation device or grating 13 comprises pillars 11 and an empty space 12 intended for the evacuation of the unfused powder arranged between the pillars 11.

[0083] Each pillar 11 comprises a body 14 which has a first end 15, forming a base connected, in the example illustrated, to the manufacturing plate 2, and a second end 16 for connecting the evacuation device 13, opposite the first end 15, which is connected to the support 3.

[0084] Preferably, the plurality of pillars 11 are interconnected so as to form a single, one-piece structure.

[0085] The part 1, the support 3, the pillars 11 and the manufacturing plate 2 advantageously form a single-piece assembly.

[0086] The cells open into the empty space 12, allowing the evacuation of the unfused powder from the cells to the outside of the assembly formed by the part 1, the support 3, the pillars 11 and the manufacturing plate 2.

[0087] The presence of the evacuation device 13 allows the evacuation of the unfused powder trapped in the support 3 as soon as the manufacture of the part 1 is completed.

[0088] The powder trapped in the cells of the alveolar structure of the support 3 escapes into the empty space 12 and can be evacuated to the periphery of the evacuation device 13.

[0089] The recovered powder can thus be recycled and reused.

[0090] Preferably, the dimensions of the body 14 decrease from the second end 16 towards the first end 15, which makes it possible to obtain a larger empty space 15 around the pillars 11 and facilitate the evacuation of the unfused powder.

[0091] According to the first embodiment illustrated in [Fig.3], the base of the pillars 11 is circular and the second end 16 is cruciform.

[0092] In the illustrated example, the body 14 comprises four fins 14a, 14b, 14c and 14d extending radially on the body 14, and extending axially between the base and one of the four branches 16a, 16b, 16c and 16d forming the second cruciform end 16.

[0093] Each of the four branches 16a, 16b, 16c and 16d which form the second cruciform end 16 of the pillars 11 is extended by one of the four branches 16a, 16b, 16c and 16d forming the second cruciform end 16 of an adjacent pillar 11.

[0094] Each pillar 11 is surrounded by eight adjacent pillars 11, and each cell of the honeycomb structure of the support 3 is bordered by four of the plurality of pillars 11.

[0095] Four of the eight adjacent pillars 11 of a pillar 11 are directly connected to the latter.

[0096] Advantageously, the second end 16 of each pillar 11 can be connected to an intersection of two of the side walls 3' of the honeycomb structure of the support 3.

[0097] Preferably, the alveolar structure of the support 3 comprises a pattern as illustrated in [Fig.2] according to which the side walls 3' intersect to form right angles.

[0098] The cross shape of the second end 16 of the four pillars 11 bordering a cell advantageously makes it possible to extend the shape of the cell, increasing the volume of the empty space 15 and facilitating the evacuation of the unfused powder.

[0099] [Fig.4] illustrates a second embodiment of the evacuation device 13.

[0100] The evacuation device 13 may comprise pillars 11 comprising a second end 16 forming a star comprising three branches 17a, 17b and 17c arranged at equal distances.

[0101] The body 14 comprises three fins each extending from the base towards one of the three branches 17a, 17b and 17c.

[0102] The base of the pillars 11 is preferably circular.

[0103] Preferably, the honeycomb structure of the support 3 connected to the evacuation device illustrated in [Fig.4] is a honeycomb structure.

[0104] By honeycomb alveolar structure is meant a structure comprising hexagonal cells.

[0105] Each hexagonal cell is formed by six 3' side walls.

[0106] In [Fig.4], only a part of the pillars 11 of the evacuation device 13 have been shown for better visibility of the honeycomb alveolar structure of the support 3.

[0107] Advantageously, the cellular structure of the support 3 may comprise a first portion 5 contiguous to the part 1 and comprising a number of side walls 3' greater than the number of side walls 3' of a second portion 6 of the cellular structure of the support 3 contiguous to the manufacturing plate 2.

[0108] With reference to [Fig.5], the part 1 may comprise a vertical portion 4a and a horizontal portion 4b extending from the vertical portion 4a and parallel to the plane passing through the manufacturing plate 2.

[0109] The first portion 5 is contiguous to the horizontal portion 4b.

[0110] The first surface 5a attached to the part 1, and in particular attached to the portion ho rizontale 4b in the illustrated example, is carried by the first portion 5.

[0111] In the illustrated embodiment, the first surface 5a is an upper surface of the support 3.

[0112] In addition, the second surface 6a attached to the manufacturing plate 2 is carried by the second portion 6.

[0113] In the illustrated embodiment, the second surface 6a is a lower surface of the support 3.

[0114] As illustrated in [Fig.6], the support 3 further comprises an intermediate portion 7 positioned between the first and second portions 5 and 6. The intermediate portion 7 is contiguous to the first and second portions 5 and 6.

[0115] The number of side walls of the alveolar structure decreases from the first portion 5 to the second portion 6, passing through the intermediate portion 7, so that the size of the alveoli increases from the first portion 5 to the second portion 6, passing through the intermediate portion 7.

[0116] The size of the cells is considered according to a cross section of the support 3, perpendicular to the longitudinal axis of the cells.

[0117] The first portion 5, the second portion 6 and the intermediate portion 7 form a single-piece assembly.

[0118] The greater number of side walls in the first portion 5 contiguous to the horizontal portion 4b of the part 1 makes it possible to locally increase the density of the support 3 to better diffuse the heat produced by the fusion bath, which makes it possible to avoid overheating of the part 1 during its manufacture by laser fusion on a powder bed.

[0119] The number of upper side walls in the first portion 5 further maximizes the grip and therefore the mechanical support of the part 1 on the support 3.

[0120] This makes it possible to avoid the collapse, during their construction, of portions of the part 1 in overhang, extending in a plane forming an angle less than or equal to 90° relative to the plane passing through the manufacturing plate 2, and in particular the portions extending in a plane forming an angle less than or equal to 45° particularly subject to collapse, and to improve the surface condition locally.

[0121] Furthermore, the evolution of the size of the cells by modification of the number of side walls 3' makes it possible to have a variation of the cell size over the height of the support 3 without it being necessary to carry out an enlargement of the surface projected on the manufacturing plate 2 and an enlargement of the manufacturing plate 2.

[0122] The evolution of the size of the cells of the support 3 also makes it possible to confer both a density of side walls 3' sufficient in contact with the part 1 to limit the overheating effects, and a larger cell size near the manufacturing plate to facilitate depowdering and evacuation of the powder by the evacuation device 13.

[0123] Advantageously, the first portion 5, the second portion 6, and preferably the intermediate portion 7, of the alveolar structure of the support 3 may comprise a common pattern, such as a pattern according to all or part of the side walls 3' intersect to form right angles as illustrated in [Fig.2].

[0124] In the illustrated example, the second portion 6 comprises a right-angled pattern as illustrated in [Fig.2].

[0125] The intermediate portion 7 comprises a number of side walls 3' greater than that of the second portion 6 which is contiguous to the manufacturing plate 2.

[0126] As shown in [Fig.7], the pattern of the intermediate portion 7 comprises the pattern illustrated in [Fig.2], and additional 3' side walls form an additional grid pattern 9. The additional 3' side walls intersect to form right angles, which results, in the intermediate portion 7, in cells four times smaller than the cells of the second portion 6.

[0127] In addition, the first portion 5, in contact with the horizontal portion 4b of the part 1, has a number of side walls 3' greater than that of the intermediate portion 7.

[0128] As shown in [Fig.8], the pattern of the first portion 5 comprises the pattern illustrated in [Fig.2], and additional side walls form another additional grid pattern 10. The additional side walls 3' intersect to form right angles, which results, in the first portion 5, in cells four times smaller than the cells of the intermediate portion 7.

[0129] The additional patterns 9 and 10 of the first portion 5 and of the intermediate portion 7 are formed by additional side walls 3' strictly parallel or perpendicular to the side walls common with the second portion 6.

[0130] Alternatively, the additional patterns 9 and 10 of the first portion 5 and of the intermediate portion 7 may be formed by additional 3' side walls which are not parallel or not perpendicular to the 3' side walls common with the second portion 6.

[0131] In alternative embodiments, at least one of the first portion 5, second portion 6 and intermediate portion 7 of the part 1 may comprise two or more coexisting right-angled patterns. The coexistence of the patterns may result in the appearance of various shapes in the alveolar structure considered along a transverse plane of the support 3, such as hexagonal, triangular, etc. alveolar shapes.

[0132] In the example illustrated in Figures 9, 10 and 11, two coexisting right-angled patterns are positioned at an angle of 45° to each other and resulting in a plurality of triangular-shaped cells.

[0133] Given the 45° angle between the two coexisting patterns, several cell sizes coexist in the alveolar structure of the first portion 5.

[0134] The patterns of the alveolar structure of the first portion 5 can be chosen so as to limit overheating of the part 1 as much as possible, and in particular chosen according to the architecture of the portion of the part 1 forming a lower or equal angle relative to the manufacturing plate 2.

[0135] In the example illustrated, the side walls 3' of the first portion 5, of the second portion 6 and of the intermediate portion 7 extend in a plane forming an angle other than 90° with the plane of each of the outer walls, so that the side walls and the outer walls are neither parallel nor perpendicular.

[0136] Preferably, the thickness of the walls of the alveolar structure is 2 mm maximum, more preferably between 0.05 and 2 mm.

[0137] Of course, the thickness value of the walls can be adjusted according to the nature of the support material and / or the nature and architecture of the part to be manufactured and supported.

[0138] Preferably, the width of the cells of the first portion 5 is between 0.4 and 5 mm, preferably between 0.5 and 2.5 mm, more preferably still between 0.6 and 0.8 mm.

[0139] Preferably, the support 3 comprises external walls 3a, 3b delimiting the periphery of the cellular structure so that all the cells of the support 3 are closed and retain all of the powder resulting from the manufacturing.

[0140] The manufacturing method according to the invention advantageously comprises a decoupling step carried out on the intermediate product. The support 3, the evacuation device 13 and the manufacturing plate 2 are removed to recover the part 1.

[0141] The decoupling can be carried out by machining, electroerosion and / or manual adjustment.

[0142] Of course, the different characteristics, variants and / or embodiments of the present invention can be associated with each other in various combinations to the extent that they are not incompatible or exclusive of each other.

Claims

Claims

1. Device for removing powder from a support for additive manufacturing of a part by laser fusion on a powder bed, comprising: a plurality of pillars (11), each pillar (11) comprising a body (14) having a first end (15) forming a base and a second end (16) for connecting the removal device to the support (3) opposite the first end (15), and an empty space (12) intended for removing unfused powder arranged between the pillars (11).

2. Evacuation device according to claim 1, in which the dimensions of the body (14) of the pillars (11) decrease from the second end (16) towards the first end (15).

3. A drain device according to claim 1 or 2, wherein the body (14) comprises at least three fins (14a, 14b, 14c and 14d) each extending from the base to the second end (16).

4. A drain device according to claim 3, wherein the second end (16) is cruciform, the body (14) comprising four fins (14a, 14b, 14c and 14d) each extending from the base towards one of the four branches (16a, 16b, 16c and 16d) forming the second cruciform end (16), preferably the base of the pillars (11) being circular.

5. Evacuation device according to claim 3, in which the second end is formed by a star having three branches (17a, 17b and 17c), the body (14) comprising three fins each extending from the base towards one of the three branches (17a, 17b and 17c) forming the second end (16), preferably the base of the pillars (11) being circular.

6. Support assembly for additive manufacturing of a part by laser powder bed fusion, comprising: a support (3) having a honeycomb structure comprising a plurality of side walls (3') forming cells, the support (3) comprising a first surface (5a) for supporting the part (1) and a second surface (6a) opposite the first surface (5a), and an evacuation device according to any one of claims 1 to 5, the second end (16) of the pillars (11) being connected to the second surface (6a) of the support (3), the evacuation device (13) and the support (3) being in one piece.

7. A support assembly according to claim 6, wherein each cell of the honeycomb structure of the support (3) is bordered by at least three of the plurality of pillars (11).

8. A support assembly according to claim 6 or 7, wherein said side walls (3') forming the cells extend from a first portion (5) of the support (3) comprising the first surface (5a) for supporting the part (1) to a second portion (6) of the support (3) comprising the second surface (6a), the first portion (5) comprising a number of side walls greater than the number of side walls of the second portion (6) so that the size of at least a portion of the cells of the first portion (5) according to a cross section perpendicular to the longitudinal axis of the cells is smaller than the size of the cells of the second portion (6).

9. The support assembly of claim 8, wherein the cellular structure of the support (3) further comprises one or more intermediate portions (7) positioned between said first and second portions (5, 6), the number of side walls (3') decreasing from the first portion (5) to the second portion (6) so that the size of the cells of each of the portions (5, 6, 7) increasing from the first portion (5) to the second portion (6).

10. A support assembly according to any one of claims 6 to 9, wherein the cross-section of the honeycomb structure of the support (3) comprises a right-angled pattern according to which all or part of the side walls (3') intersect at right angles.

11. A support assembly according to any one of claims 6 to 9, wherein the cross-section of the honeycomb structure of the support (3) comprises a honeycomb pattern.

12. Intermediate product for additive manufacturing of a part (1) by laser powder bed fusion, comprising a support assembly according to any one of claims 6 to 11 and the part (1), the support assembly and the part (1) being in one piece.

13. A method of manufacturing a part (1) by laser powder bed fusion comprising: forming the part (1) by layer-by-layer fusion of a powder using a laser and, simultaneously with the formation of the part (1): forming a support assembly according to any one of claims 6 to 11.