Additive Manufacturing Support Structures via Common Layers
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Solution Overview
Problem
Existing additive manufacturing methods face challenges in minimizing adverse effects from support structures during the building process, particularly in achieving mechanical stability and aesthetics in dental restorations.
Innovation Solution
A method of building up physical objects by additive manufacturing where the support structure is directly connected to the object through common layers, allowing for flexible positioning and easy removal of support structures without affecting the object's surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If support structures are used to support overhanging portions during additive manufacturing, then mechanical stability during the build process is improved, but the object's surfaces may be affected by residues from support structure removal
Solution Approach 1:
The support structure is extracted as a separate, removable component that connects to the object through a dedicated connection element rather than being integrated into the object's functional surfaces. This allows the support structure to be removed after building without leaving residues on the object's surfaces, thus maintaining surface quality while providing mechanical stability during the build process.
Solution Approach 2:
A connection element acts as an intermediary between the support structure and the object. This intermediary component provides a controlled interface for support attachment, enabling the support structure to fulfill its mechanical stability function while being easily removable without affecting the object's surfaces. The connection element mediates between the need for support and the need for surface quality.
2Ease of manufacture
If support structures are built before the object during additive manufacturing, then the build process can be simplified, but flexibility in positioning support structures is reduced
Solution Approach 1:
The connection element is designed and positioned in advance within the object model, creating predetermined attachment points for the support structure. This preliminary action allows the support structure to be flexibly positioned and adapted to different object geometries while maintaining a simplified build process, as the connection points are pre-planned rather than requiring complex real-time adjustments.
3Stability of the object's composition
If traditional support structures are used in dental restorations, then mechanical support during building is provided, but aesthetic requirements concerning color shading and translucency are compromised
Solution Approach 1:
The support structure is extracted as a separate component that does not become part of the final dental restoration. The connection element provides a controlled interface that allows the support structure to be removed after building, ensuring that no support residues remain on the dental restoration's surfaces, thus preserving aesthetic quality while providing necessary mechanical support during manufacturing.
Solution Approach 2:
The connection element serves as an intermediary that enables the support structure to fulfill its mechanical function without compromising the dental restoration's aesthetics. By providing a dedicated connection interface, the intermediary allows for clean separation between the support structure and the restoration, ensuring that aesthetic surfaces remain free from support residues.
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 method enhances the flexibility in positioning support structures, facilitates their removal without damaging the object, and ensures mechanical stability and aesthetic quality in dental restorations.
Implementation Method 1
Stereolithography generally uses light for hardening light hardenable or photopolymerizable resins. Data based on computer aided design and/or computer aided manufacturing (CAD/CAM) are used to project a light pattern on a layer of light hardenable resin. The photosensitive resin typically solidifies in consequence of the exposure of the light so that a layer of solidified resin according to the pattern is formed.
Data Source
AI summary
A method of building up a physical object by additive manufacturing which has the steps of building up the object and at least one support structure layer by layer along a build axis. The support structure supports the object relative to a build platform. During building up the object and the at least one support structure a connection is provided between the support structure and the object by a plurality of layers each of which being a common layer of the object and the support structure.