3D Printing Support Generation for Sintering Deformation Control
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Solution Overview
Problem
Challenges in 3D printing of metal objects include geometrical accuracy and manufacturing consistency, with techniques often resulting in porous parts that undergo significant volumetric shrinkage during sintering, leading to issues like gravitational sag, gravitational slump, and surface drag due to insufficient support.
Innovation Solution
Automated generation of support structures that can be dynamically created and removed to minimize deformation during manufacturing, using a method that determines starting positions based on predicted displacements and traverses a cost field to generate a support structure that reduces material consumption and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If support structures are added to prevent deformation during sintering, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary analysis of the 3D model to predict displacement during sintering, then pre-calculates the optimal support structure configuration before manufacturing. This preliminary action ensures that supports are strategically placed to counteract anticipated deformation, improving geometrical accuracy without adding unnecessary complexity
Solution Approach 2:
Instead of providing uniform support throughout the entire model, the system applies support structures only at specific locations where displacement is predicted to occur. This localized approach maintains manufacturing precision at critical areas while minimizing overall device complexity
2Manufacturing precision
If support structures are used during manufacturing, then manufacturing precision is improved, but loss of substance increases due to additional material consumption
Solution Approach 1:
The system generates support structures only at specific locations where they are most needed to maintain manufacturing consistency, rather than providing comprehensive support throughout the entire build volume. This localized support approach reduces material consumption while maintaining precision at critical areas
Solution Approach 2:
The system applies a partial support strategy, providing support only where displacement prediction indicates it is necessary, rather than using excessive support throughout the entire model. This reduces material consumption while maintaining sufficient manufacturing precision
3Productivity
If automated support generation is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The system performs automated support structure generation by autonomously analyzing the 3D model, predicting displacement, and generating support configurations without requiring manual intervention. This self-service capability improves productivity by eliminating time-consuming manual support design while the automation handles the complexity internally
Data Source
AI summary
Examples of methods for generating supports are described herein. In some examples, a method includes determining a starting position from a set of voxels of a three-dimensional (3D) object model to be additively manufactured. In some examples, the method also includes generating a support for the 3D object model by traversing a cost field from the starting position.