Additive Manufacturing Support Structure with Breakable Lamellar Zone
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Solution Overview
Problem
Additive manufacturing requires time-consuming support structures for parts with overhangs, which increases production costs and time.
Innovation Solution
A support structure comprising a breakable lamellar zone, an intermediate porous zone, and an anchoring zone, produced using additive manufacturing, with specific energy density and thickness ratios to facilitate part production while allowing easy separation and anchoring, optimizing the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support structure is used for parts with overhangs in additive manufacturing, then the part can be manufactured successfully, but the production time increases significantly
Solution Approach 1:
The support structure is divided into three distinct zones with different structures: a breakable zone with lamellar structure (low energy density 10-25%) for easy removal, an intermediate porous zone (15-60% energy density) for structural transition, and an anchoring zone (90-110% energy density) for secure attachment. This segmentation allows each zone to perform its specific function optimally while reducing overall manufacturing time.
Solution Approach 2:
Different zones of the support structure have different local properties tailored to their functions: the breakable zone has low density and lamellar structure for easy breaking, the intermediate zone has porous structure for gradual transition, and the anchoring zone has high density for strong attachment. This local quality differentiation enables the support to be both strong where needed and easy to remove where required.
2Reliability
If a support structure is used for parts with overhangs, then the part can be manufactured successfully, but the manufacturing cost increases
Solution Approach 1:
The invention changes the volumetric energy density parameter across different zones of the support structure. The breakable zone uses 10-25% of the energy density used for the part, the intermediate zone uses 15-60%, and the anchoring zone uses 90-110%. This parameter variation creates the desired structural differences without requiring additional materials or complex post-processing, reducing manufacturing costs.
3Strength
If a traditional solid support structure is used, then the part is well-supported during manufacturing, but the support is difficult and time-consuming to remove
Solution Approach 1:
The support structure is segmented into zones with different structural characteristics. The breakable zone contains spaced-apart solid portions creating a lamellar structure that provides sufficient support during manufacturing but allows easy separation afterward. This segmentation eliminates the need to remove large solid support blocks, significantly reducing removal time.
Solution Approach 2:
The breakable zone is designed as a disposable element that serves its support function during manufacturing and then is easily discarded. By creating a zone with low energy density (10-25%) and lamellar structure, the invention makes the support easy to break and remove, treating it as a temporary, disposable component rather than a permanent fixture.
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
The support structure enables quick and cost-effective production of parts with overhangs by maintaining the part during manufacturing and facilitating easy separation, reducing production time and costs.
Implementation Method 1
additive manufacturing consists of manufacturing a part by successively superimposing layers of powder which are melted locally
Implementation Method 2
consolidation is done, for example, layer by layer, by total or partial selective fusion carried out with a consolidation source (high-power laser beam, electron beam, etc.)
Implementation Method 3
a breakable zone with a lamellar structure comprising a plurality of solid portions spaced apart from each other which do not belong to the same block, the breakable zone being suitable for holding, during its manufacture, a part intended to be produced by additive manufacturing
Implementation Method 4
an intermediate zone with a single-block porous structure... The intermediate zone can have a porosity of between 0.5 and 5%, preferably between 1 and 2%
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to an additive manufacturing substrate (1) which, upon a plate of an additive manufacturing machine, comprises a stack produced by means of additive manufacture, comprising: - a divisible zone having a structure designed to hold, during manufacture, a part (100) which is to be made by means of additive manufacture, and, between the plate and the zone with the divisible structure, - an intermediate zone with a porous structure.