Additive Manufacturing Support Structure with Segmented Pillars
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Solution Overview
Problem
In additive manufacturing, existing supporting structures require excessive material for object support, leading to material waste and increased printing costs, as well as complicating the removal process due to their complexity.
Innovation Solution
A supporting structure is formed with an array of spire-shaped air pockets and pillars, where the pillars are reinforced with model material to provide structural support while minimizing the volume of support material needed, and a contact pad is used to interface with the object, allowing for efficient material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional supporting structures are used in additive manufacturing, then object support during printing is ensured, but material waste increases and printing costs increase
Solution Approach 1:
The supporting structure is divided into multiple discrete pillars arranged in arrays rather than continuous support material. Each pillar is a separate element that can be individually optimized, and the segmented structure uses significantly less material while maintaining support functionality during additive manufacturing
Solution Approach 2:
The supporting structure incorporates air pockets within and between pillars, creating a porous configuration. This reduces the overall material volume of the support structure while maintaining structural integrity sufficient to support overhanging features during the printing process
2Reliability
If traditional supporting structures are used in additive manufacturing, then object support during printing is ensured, but printing costs increase
Solution Approach 1:
By segmenting the support structure into discrete pillars, the total material volume is reduced, directly lowering material costs. The segmented design also enables more efficient printing paths and reduced printing time, further decreasing manufacturing costs while maintaining adequate support functionality
3Reliability
If complex supporting structures are used in additive manufacturing, then object support during printing is ensured, but removal process becomes complicated
Solution Approach 1:
The segmented pillar structure consists of simple, discrete elements rather than complex continuous geometries. This segmentation makes the support structure easier to remove from the printed object, as the individual pillars can be more readily detached or dissolved without affecting the main object structure
Solution Approach 2:
The porous configuration with air pockets reduces the material density and complexity of the support structure. This porosity facilitates easier removal through dissolution or mechanical detachment, as there is less material to remove and the open structure allows better access to the interface between support and object
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 material waste and printing costs by minimizing the volume of support material required, while simplifying the removal process through the use of soluble support materials and strategically placed reinforcements.
Implementation Method 1
The support material may be a polymer, which is water-soluble and/or capable of swelling and/or breaking down upon exposure to a liquid solution, e.g. water
Implementation Method 2
The photo-initiator may enable at least partial solidification of the support material by curing with the same UV light applied to the model material
Data Source
AI summary
A supporting structure built together with an object in an additive manufacturing (AM) process and configured to support an overhang of the object is described. The supporting structure includes a first array of pillars formed with a first material and reinforced with a second material. Each of the pillars in the first array includes a top. At least a portion of the tops in the first array adjoin and define a surface on which the overhang of the object may be supported. The first material is support material.