Additive Manufacturing Support Structure for Distortion Control
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Solution Overview
Problem
Conventional additive manufacturing techniques often result in distortion and residual stress in built components due to localized heating and cooling, leading to issues like crack development and fractures, despite post-processing efforts.
Innovation Solution
The use of a support structure that couples components together and defines channels for removing additive powder, which also helps in measuring airflow or restrictions, to mitigate distortion and residual stress by restricting motion during the build process and facilitating easier post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive manufacturing techniques are used to build components layer-by-layer, then net or near net shape objects can be manufactured, but distortion and residual stress develop in the built components
Solution Approach 1:
The build assembly is segmented into multiple components (first component, second component, and support structure) that are manufactured together as separate but connected elements. This segmentation allows the support structure to be designed with specific stress-reducing functions while maintaining the net shape manufacturing advantage of additive processes
Solution Approach 2:
The support structure is designed and manufactured in advance with built-in channels for powder removal and airflow measurement capabilities. This preliminary action enables stress mitigation to occur during the manufacturing process itself, rather than requiring subsequent corrective measures
2Manufacturing precision
If support structures are used to reduce residual stress, then component distortion is mitigated, but the build assembly complexity increases
Solution Approach 1:
The support structure serves multiple functions simultaneously: it provides mechanical support during building, defines channels for powder removal, enables airflow measurement, and mitigates residual stress. This multi-functionality reduces the need for separate dedicated structures for each function, thereby limiting the increase in overall complexity
Solution Approach 2:
The support structure acts as an intermediary element between the built components and the manufacturing process. It mediates the stress effects during building and facilitates post-processing operations, simplifying the interaction between components and process rather than directly complicating the component geometry
3Manufacturing precision
If post-processing techniques are applied to mitigate stress effects, then some residual stress is reduced, but additional manufacturing steps and time are required
Solution Approach 1:
The support structure with integrated channels is designed and manufactured before the main component production. This preliminary action establishes stress-mitigation capabilities and powder removal pathways during the primary manufacturing process, reducing the need for extensive subsequent stress relief operations
Solution Approach 2:
The support structure's channel system enables the build assembly to self-manage powder removal and stress distribution during and after manufacturing. This self-service capability reduces reliance on external post-processing interventions, thereby minimizing additional time requirements
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 reduces distortion and residual stress in additively manufactured components, requiring less post-processing and resulting in more accurate, reliable, and cost-effective manufacturing with fewer sub-components and joints.
Implementation Method 1
an energy beam sinters or melts a cross sectional layer of the object being built
Implementation Method 2
direct metal laser sintering (DMLS) or direct metal laser melting (DMLM)... the energy beam sinters or melts
Implementation Method 3
As the top layer of metal cools and solidifies on the layer below
Implementation Method 4
it contracts and generates shear forces between the layers
Data Source
Figure 1
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AI summary
A build assembly (100) and a method (200) of manufacturing the same are provided. The build assembly (100) includes a first component (102), a second component (104), and a support structure (110) coupling the two components (102, 104) together to fix their relative position. The support structure (110) may be a "ghost" structure that is not connected with or does not contact the components (102, 104), but is positioned such that the components (102, 104) are restrained to prevent distortion. The support structure (110) may also be connected to the components (102, 104) and may define channels (120) for removing additive powder from within or around the components (102, 104).