3D Print Build Orientation for Orthogonal Metal Structures
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Solution Overview
Problem
Existing 3D printing techniques for complex metal structures with orthogonal surfaces face challenges such as the need for support structures, which are difficult to remove and can result in surface roughness and geometric uncertainty.
Innovation Solution
The use of specific build orientations in 3D printing, including aligned, secondary, and optimized orientations, allows for the printing of complex metal structures without internal support structures, minimizing surface distortion and geometric discontinuities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support structure is added for overhang surfaces, then the structural stability during printing is improved, but the surface finish quality deteriorates and removal becomes difficult
Solution Approach 1:
The build orientation is predetermined and optimized before the printing process begins. By calculating the optimal build orientation in advance that minimizes overhang angles, the need for support structures is reduced or eliminated, thereby preventing surface finish degradation from the outset rather than requiring post-processing removal
Solution Approach 2:
The problem is solved by changing the build orientation in the dimensional space of printing angles. By rotating the model to specific orientations (e.g., 45-degree angles), surfaces that would normally require support are repositioned to print at more favorable angles, eliminating the need for support structures
2Ease of manufacture
If support structure is used for enclosed surfaces, then the printing process can proceed, but the support removal becomes impossible
Solution Approach 1:
The build orientation is optimized before printing to ensure that enclosed surfaces do not require support structures. By pre-calculating orientations that maintain structural integrity without overhangs exceeding thresholds, the printing process can proceed for enclosed geometries without creating inaccessible support structures that would be impossible to remove
3Adaptability or versatility
If multiple support structures are added, then the printing of complex geometries becomes feasible, but the number of post-processing operations increases
Solution Approach 1:
The optimal build orientation is calculated and established before the printing process begins. This preliminary optimization minimizes the number of support structures required by selecting orientations that reduce overhangs, thereby reducing the subsequent post-processing time needed for support removal
Solution Approach 2:
The build orientation parameters (angles and directions) are optimized to minimize the quantity of support structures needed. By changing the orientation parameters to specific values that reduce overhang severity, the number of support structures is minimized, reducing post-processing operations
Data Source
AI summary
Systems, methods, and devices of additive manufacturing (3D printing) of complex structures made of surfaces including at least some of which that are orthogonal to each other. Specifically disclosed herein are build orientations used to manufacture complex metal structures with a build chamber of an additive manufacturing printer. The novel build orientations allow the fabrication of components with a minimum of support structure.