3D Printing of Overhangs and Cavities With Fewer Supports
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Solution Overview
Problem
Current 3D printing methods often require auxiliary supports to prevent deformation of printed objects, which increase manufacturing costs and time, and can restrict the design and materialization of complex structures with cavities and overhangs.
Innovation Solution
The method involves controlling the diffusion of elements into metal alloys to create homogeneous crystal phases and metallurgical morphologies, and using energy beams to transform and densify layers of pre-transformed material, reducing porosity and defects like fractures, and forming high aspect ratio melt pools to minimize the need for auxiliary supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If auxiliary supports are used to prevent deformation during 3D printing, then the structural integrity of the printed object is improved, but the manufacturing cost and time increase
Solution Approach 1:
The invention extracts and removes the auxiliary support structures from the final printed object through post-processing steps. The supports are temporarily added during printing to enable complex geometries, then selectively removed to achieve the final design without unnecessary material or time expenditure
Solution Approach 2:
The invention performs preliminary actions by pre-calculating and pre-positioning auxiliary supports before the printing process begins. The support structures are strategically placed in advance to prevent deformation during printing, allowing the main object to be printed with proper structural integrity from the start
2Reliability
If auxiliary supports are used to prevent deformation during 3D printing, then the structural integrity of the printed object is improved, but the manufacturing cost increases
Solution Approach 1:
The invention extracts and removes the auxiliary support structures from the final printed object through post-processing steps. The supports are temporarily added during printing to enable complex geometries, then selectively removed to achieve the final design without unnecessary material or time expenditure
Solution Approach 2:
The invention changes material parameters by using materials with different properties for the main object and auxiliary supports. This allows selective removal of supports through processes like dissolving or melting, reducing the overall manufacturing cost by minimizing material waste and post-processing complexity
3Reliability
If auxiliary supports are used to prevent deformation during 3D printing, then the structural integrity of the printed object is improved, but the design freedom for complex structures is restricted
Solution Approach 1:
The invention segments the printing process into distinct phases: object printing, support addition, and support removal. This segmentation allows complex structures with cavities and overhangs to be printed by temporarily adding supports only where needed, then removing them to achieve the desired complex geometry without compromising structural integrity
Solution Approach 2:
The invention uses auxiliary supports as intermediary elements that facilitate the printing of complex structures. These supports act as temporary mediators that enable the creation of overhangs and cavities during printing, then are removed to reveal the final complex geometry, expanding design freedom
4Manufacturing precision
If energy beams are used to transform and densify layers of material, then the porosity and defects are reduced, but the energy consumption increases
Solution Approach 1:
The invention uses periodic action by applying energy beams in pulsed or intermittent cycles rather than continuous exposure. The energy beam transforms and densifies material layers in periodic cycles, allowing heat diffusion and material relaxation between pulses, which reduces overall energy consumption while achieving uniform density and eliminating porosity
Solution Approach 2:
The invention exploits phase transitions by using energy beams to repeatedly melt and solidify material layers during the densification process. This controlled phase transition approach ensures complete elimination of porosity and defects while optimizing energy consumption by leveraging the material's own phase change properties
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 generation of 3D objects with reduced deformation and minimized auxiliary supports, enabling the creation of complex structures with diminished design and fabrication constraints, resulting in higher density and reduced porosity.
Implementation Method 1
controlling the diffusion of elements into metal alloys to create homogeneous crystal phases and metallurgical morphologies
Implementation Method 2
using energy beams to transform and densify layers of pre-transformed material, reducing porosity and defects like fractures
Data Source
AI summary
The present disclosure provides three-dimensional (3D) printing methods, apparatuses, systems and/or software to form one or more complex three-dimensional objects. The three-dimensional object may be formed by three-dimensional printing one or more methodologies. The three-dimensional object may comprise an overhang portion and/or cavity ceiling with diminished deformation and/or auxiliary support structures.