Additive Manufacturing Support Structure for Distortion Control

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Solution Overview

Problem

Additive manufacturing of metal components often results in significant build stresses that cause distortion, particularly in large aspect ratio shapes, which conventional support structures struggle to effectively manage during the manufacturing process.

Innovation Solution

A method involving the design of a support structure with a hook structure comprising an elongate arm and a hook that abuts the component's distortion surface, where the elongate arm's shrinkage opposes the direction of distortion, minimizing component distortion, and iterative design adjustments based on predictive simulations or experimental manufacturing to ensure distortion falls below a threshold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional support structures are used to restrain distortion during additive manufacturing, then component distortion is restrained, but the support structure requires significant machining to remove and the component finishing time increases

Engineering Contradiction:

Improvecomponent distortion controlVSAvoidsupport structure removal and finishing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The hook structure is designed with an elongate arm that extends in the direction opposing distortion, creating preliminary counteracting forces during manufacturing. The hook protrusion is positioned to abut the distortion surface in advance, preventing distortion before it occurs rather than correcting it afterward

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention converts the harmful shrinkage forces that cause distortion into a beneficial mechanism. The elongate arm is designed to shrink during additive manufacturing, and this shrinkage generates a force that opposes distortion. The hook structure allows the support to be easily removed by breaking the bond, turning what would be a time-consuming removal process into a simple operation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Manufacturing precision

If the contact area between support structure and component is increased to improve distortion restraint, then distortion control improves, but the machining time to remove support structure increases

Engineering Contradiction:

Improvedistortion surface controlVSAvoidsupport structure removal ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The hook structure concentrates the contact area into a localized protrusion that abuts the distortion surface at a specific point or small region. This localized contact provides effective distortion restraint at the critical area while minimizing the overall contact area, making support removal easier and reducing machining requirements

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If the elongate arm length is increased to provide greater opposing force against distortion, then distortion minimization improves, but the additive manufacturing time increases

Engineering Contradiction:

Improvedistortion force oppositionVSAvoidadditive manufacturing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The elongate arm length is optimized to a minimum effective extent that provides sufficient shrinkage force to oppose distortion while minimizing the volume of material that needs to be manufactured. The parameters of the hook structure (protrusion size, arm thickness, length) are tuned to achieve the required force with minimal material, balancing distortion control with manufacturing efficiency

Inventive Principle:

Principle #35Parameter changes

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 effectively reduces component distortion during additive manufacturing, allowing for easier removal of the support structure and finishing, while optimizing the force profile applied to minimize distortion, thereby improving the manufacturing process efficiency.

Implementation Method 1

shrinkage of the elongate arm during additive manufacture provides a force to the portion of the component, via the hook, to minimise distortion of the portion of the component

Methodology Applied

Scientific EffectShrinkage: Thermal Contraction

Implementation Method 2

additive manufacturing, by melting and fusing powder from a build plate, the component and the support structure

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20240051027A1A method of manufacturing a component

Publication Date: 2024.02.15 ROLLS ROYCE PLC

AI summary

Disclosed is a method of manufacturing a component, the method comprising: determining a predicted direction and extent of distortion of a portion of the component; designing a support structure based on the predicted direction and extent of distortion of the portion of the component; additive manufacturing, by melting and fusing powder from a build plate, the component and the support structure. The support structure comprises, a hook structure comprising an elongate arm and a hook protruding from the elongate arm. The hook is deposited to abut a distortion surface of the component to restrain distortion of the component. The distortion surface is the furthest in the direction of distortion of the component. The elongate arm is deposited to extend from the hook in a direction having a vector component opposing the direction of distortion such that shrinkage of the elongate arm provides a force to minimise distortion of the component.