Additive Manufacturing Support Structures for Tall Objects
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Solution Overview
Problem
Additive manufacturing processes face challenges with objects having large height-to-width aspect ratios, as they are prone to damage from recoater arms due to lateral forces, which can cause tipping or bending, even when vertically supported.
Innovation Solution
The implementation of support structures that connect objects via horizontal and vertical supports built in layers, with a height-to-width aspect ratio threshold, to stabilize tall objects and prevent damage from recoater forces, and the use of various support types such as scaffolding, tie-down, break-away, and lateral supports to manage thermal and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If objects with large height-to-width aspect ratios are fabricated using additive manufacturing, then complex geometries can be achieved, but the objects are prone to damage from recoater arms due to lateral forces causing tipping or bending
Solution Approach 1:
The support structure is divided into multiple discrete support members arranged in a pattern around the object. Each support member independently provides stabilization, and collectively they form a distributed support system that prevents tipping and bending while allowing the object to achieve complex geometries with high aspect ratios
Solution Approach 2:
The support members act as intermediary elements between the recoater arm and the object being fabricated. These supports absorb and distribute the lateral forces from the recoater arm, preventing direct transmission of damaging forces to the object while allowing the fabrication process to continue
2Reliability
If support structures are added to stabilize tall objects, then object stability improves, but device complexity increases
Solution Approach 1:
Support members are strategically placed only at critical locations where stabilization is needed, rather than providing uniform support throughout. The support pattern is optimized to provide maximum stability with minimum complexity, placing supports at corners and key structural points of the object being fabricated
Solution Approach 2:
The support structure provides more stabilization than the absolute minimum required, using a pattern of support members that exceeds the theoretical minimum but maintains simplicity. This partial support approach is sufficient to prevent tipping and bending while avoiding the complexity of fully enclosing the object with supports
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
The described support structures effectively stabilize objects with high aspect ratios, preventing damage from recoater forces and ensuring successful layer-by-layer fabrication, while allowing for easy removal and post-processing, suitable for complex geometries like aircraft parts.
Implementation Method 1
an energy beam, for example, an electron beam or electromagnetic radiation such as a laser beam, to sinter or melt a powder material
Implementation Method 2
sintering entails fusing (agglomerating) particles of a powder at a temperature below the melting point of the powder material
Implementation Method 3
melting entails fully melting particles of a powder to form a solid homogeneous mass
Implementation Method 4
objects having large height-to-width aspect ratios, as they are prone to damage from recoater arms due to lateral forces
Data Source
Figure 1
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AI summary
The present disclosure generally relates to methods for additive manufacturing (AM) that utilize connecting support structures (230, 240) in the process of building objects (210), as well as novel connecting support structures (230, 240) to be used within these AM processes. The connecting support structures include two fused connections to the object (210) and an axial direction between the fused connections, a perimeter of fused material about the axial direction, and unfused powder or air completely surrounding the perimeter of fused material.