Additive Build Part Support Placement by Beam Incidence Angle
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Solution Overview
Problem
Additive manufacturing of three-dimensional build parts with internal voids and protruding appendages faces challenges in providing sufficient mechanical support during the build process, leading to deformation and irregularities due to temperature gradients and phase changes, which results in costly and labor-intensive support removal post-processing.
Innovation Solution
An additive manufacturing system that determines geometrical characteristics, such as the angle of incidence between the electromagnetic energy source and the build part's surface, to precisely locate support material during the build process, reducing the need for external supports and improving surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external supports are constructed during the additive manufacturing build process, then overhanging features are properly supported and secured in place, but the supports must be removed during post-processing which reduces manufacturing efficiency and increases production costs
Solution Approach 1:
The build part itself provides support for its overhanging features through strategically positioned internal support structures that are integrated into the part geometry. The support function is performed by the part's own material rather than separate external support structures, eliminating the need for post-processing removal while maintaining structural integrity during building.
Solution Approach 2:
The support function is extracted from external support structures and integrated directly into the build part's internal geometry. By removing the separation between build part and support structures, the patent eliminates the harmful post-removal step while preserving the necessary support function during manufacturing.
2Reliability
If external supports are constructed during the additive manufacturing build process, then overhanging features are properly supported and secured in place, but the removal of supports is costly, difficult, time intensive, and labor intensive
Solution Approach 1:
The build part's internal geometry provides self-support for overhanging features through integrated support structures. This eliminates the need for separate external supports that would require time-consuming post-processing removal, thereby reducing post-processing time while maintaining necessary structural support during building.
Solution Approach 2:
Support structures are pre-integrated into the build part's internal geometry before the building process begins. By planning and incorporating support functions into the part design beforehand, the patent eliminates the need for subsequent support removal operations, reducing post-processing time and labor.
3Reliability
If external supports are constructed during the additive manufacturing build process, then overhanging features are properly supported and secured in place, but residual metal from the supports left intact on the build part may degrade the quality of the finished product
Solution Approach 1:
The support function is extracted from external support structures and integrated into the build part's internal geometry. This integration ensures that support structures become indistinguishable from the final part geometry, eliminating residual metal degradation issues while maintaining necessary support during building.
Solution Approach 2:
The support structures are merged with the build part's internal geometry, making them an integral part of the final product rather than separate temporary elements. This merging ensures that no residual support material degrades surface quality, as the support structures become part of the intended final geometry.
4Reliability
If support material is used during the additive manufacturing build process, then mechanical support is provided for overhanging features, but the amount of support material increases device complexity and post-processing requirements
Solution Approach 1:
The build part's internal geometry provides self-support through integrated structures, eliminating the need for separate external support systems. This reduces device complexity by removing the distinction between build part and support structures, while maintaining necessary mechanical support during the building process.
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 the amount of support material required, increases production efficiency, and enhances surface quality by accurately determining support locations based on geometrical characteristics, minimizing post-processing time and costs.
Implementation Method 1
The deposited layers are selectively fused via the application of a focused energy source, such as a laser, which heats and bonds the material.
Implementation Method 2
temperature gradients and phase changes as the fused layers cool down cause internal stresses within the build part
Implementation Method 3
The internal stresses can thermally contract and/or distort the structure causing irregularities that deviate from the intended shape in the build plan.
Data Source
Figure 1
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AI summary
An additive manufacturing system (100) comprising: one or more processors (118) configured to determine one or more geometrical characteristics of each of multiple segments (202, 204, 206) of a build part (116) at a candidate position of the build part relative to an additive manufacturing instrument (101), wherein the one or more geometrical characteristics include an angle of incidence (208, 246) between a beam line (210, 248) extending from an electromagnetic energy source (106) of the additive manufacturing instrument and a surface normal (212, 250) of a respective skin (214) of the corresponding segment proximate to the beam line, wherein the one or more processors are configured to determine, based on one or more geometrical characteristics of the segments at the candidate position, one or more locations of support material (270) to be formed adjacent the build part during a build process of the build part.