Additive Manufacturing Support Layers for Removable Multi-Material Builds
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Solution Overview
Problem
Conventional additive manufacturing techniques, such as selective laser melting (SLM), face challenges in removing support structures due to their fusion with the article, leading to increased material consumption, contamination, and environmental hazards, while limiting the creation of complex shapes and structures.
Innovation Solution
The use of a distinct second material as a support structure, which can be easily removed and recycled, allows for the selective deposition and fusion of multiple materials within each layer, reducing material waste and enabling the formation of complex geometries by defining concavities and selectively fusing particles with different properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If support structures are formed from the same material as the article in conventional SLM, then structural support and anchoring are provided, but material consumption increases and removal becomes problematic
Solution Approach 1:
The patent segments the material system into two distinct materials: a build material for the article and a support material for support structures. This segmentation allows the support structures to be formed from a different material that can be easily removed, thereby reducing material consumption while maintaining structural support functionality during the additive manufacturing process.
Solution Approach 2:
The patent extracts the support structure material from the build material by introducing a separate support material. This extracted support material can be selectively removed after manufacturing, reducing waste of the build material while the support structures continue to provide necessary structural support during the layer-by-layer formation process.
2Strength
If support structures are formed from the same material as the article, then structural support is provided, but removal becomes difficult due to fusion and inaccessibility
Solution Approach 1:
The patent segments the material system into a build material and a support material with different properties. The support material is specifically selected to be removable through dissolution or other separation methods, making support structure removal easy while the support structures continue to provide structural support during manufacturing.
Solution Approach 2:
The patent introduces a support material that acts as an intermediary substance between the build material and the removal process. This intermediary material provides structural support during manufacturing but can be easily separated through dissolution or other methods, facilitating easy removal of support structures after the article is formed.
3Device complexity
If conventional SLM spreads a single material layer, then process simplicity is maintained, but material versatility and complex structure formation are limited
Solution Approach 1:
The patent applies local quality by allowing different materials to be deposited in different regions of the same layer. The support material is selectively deposited in areas where support structures are needed, while the build material is deposited elsewhere, enabling material versatility without significantly complicating the overall layer-by-layer manufacturing process.
Solution Approach 2:
The patent uses composite materials by combining a build material and a support material in the same additive manufacturing process. This allows the formation of complex structures with different material properties in different regions, enhancing material versatility while maintaining a relatively simple layered manufacturing approach.
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 facilitates the efficient removal of support structures, reduces material consumption, and enables the creation of articles with enhanced structure and function by allowing multiple materials to be used within a layer or across layers, improving the recycling and reuse of materials.
Implementation Method 1
a fusing means for fusing some of the particles of the levelled first material in the first concavity by at least partially melting said particles
Data Source
AI summary
An apparatus (100) for additive manufacturing of a part of an article from a first material comprising particles having a first composition is provided. The apparatus (100) comprises a layer providing means (110) for providing a first support layer from a second material comprising particles having a second composition, wherein the first composition and the second composition are different. The apparatus (100) comprises a concavity defining means (120) for defining a first concavity in an exposed surface of the first support layer. The apparatus (100) comprises a depositing means (130) for depositing a part of the first material in the first concavity defined in the first support layer. The apparatus (100) comprises a levelling means (140) for selectively levelling the deposited first material in the first concavity. The apparatus (100) comprises a first fusing means (150) for fusing some of the particles of the levelled first material in the first concavity by at least partially melting said particles, thereby forming a first part of the layer of the article. In this way, the second material may be thus used to provide a support structure during additive manufacturing of the part of the article.