Chain-like Support Structure for Additive Manufacturing
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Solution Overview
Problem
Conventional methods for removing support structures in additive manufacturing are laborious, time-consuming, and error-prone, especially for complex components, as they often require mechanical separation which can damage the component and is difficult for inaccessible areas.
Innovation Solution
Generating control data for additive manufacturing that includes instructions for building support structures with predetermined breaking points, allowing for easy removal by applying a force at designated access points, enabling the support structure to be pulled or pushed away from the component in a chain-like fashion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical separation methods are used to remove support structures, then the support structures can be removed from the component, but large mechanical forces act on the support structures and component which risks damaging the component and the process is laborious and time-consuming
Solution Approach 1:
The support structure is segmented into multiple individual support elements that are arranged in a grid pattern. Each support element can be independently removed or broken away, allowing the support structure to be removed in smaller increments rather than as a single large structure, thereby reducing the mechanical force required at any one time
Solution Approach 2:
The support elements are designed with specific geometric parameters including a cross-sectional shape that provides structural integrity during manufacturing but facilitates easy removal. The support elements have a height that is a multiple of the layer thickness and a cross-section that allows them to be snapped or broken away with minimal force after the component is formed
2Productivity
If conventional mechanical separation methods are used, then support structures can be removed, but the process is laborious and time-consuming especially for complex components with inaccessible areas
Solution Approach 1:
The support structure is divided into a grid of discrete support elements that can be removed independently. This segmentation allows for parallel removal operations and makes it possible to access and remove support elements in complex geometries that would be difficult to reach with conventional mechanical tools
Solution Approach 2:
The support elements are designed as temporary, disposable structures that serve their purpose during manufacturing and then can be easily discarded. They are not designed for long-term durability but rather for ease of removal, reducing the time and effort required for the removal 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 method reduces the force required for removal and allows for efficient detachment of support structures, even from complex or inaccessible areas, without damaging the component, by transmitting the force progressively through the chain-like structure.
Implementation Method 1
selective laser melting. Here, thin layers of a usually powdery build-up material are applied one on top of the other repeatedly, wherein the build-up material in each layer is selectively solidified by spatially limited irradiation of the points that, after manufacture, are intended to belong to the manufacturing product to be produced. The powder grains of the build-up material can be partially or completely melted by the local introduction of energy by irradiation
Data Source
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AI summary
A method for generating control data (PCD, PCD') for a device (4) for additive manufacturing of a component (1, 1') by selectively solidifying an assembly material (52) in an additive manufacturing process is described. In the method, the control data (PCD, PCD') are generated in such a way that they comprise instructions for the device (4) for additive manufacturing, such that the component (1, 1') is built up with at least one support structure (2, 2') mechanically connected to the component (1, 1'). The support structure (2, 2') comprises at least two support structure elements (20, 20') arranged side by side in a direction along a surface (10) of the component (1, 1'). At least one of the support structure elements (20, 20') mechanically connects the surface (10) of the component (1, 1') and the support structure (2, 2'). At least one of the support structure elements (20, 20') comprises at least one predetermined breaking point (21, 21'). The at least two support structure elements (20, 20') form together a chain-like structure (27), which can be removed from the component (1, 1') by applying a force (f) at an access point (29) of the support structure (2, 2'). Further, a method for additive manufacturing of a component (1, 1') by selectively solidifying an assembly material (52) in an additive manufacturing process is described. Furthermore, a control data generation device (63) for generating control data (PCD, PCD') for a device (4) for additive manufacturing of a component (1, 1') and a control device (61) for a device (4) for additive manufacturing of a component (1, 1') is described. In addition, a device (4) for additive manufacturing of a component (1, 1') and a computer program product comprising a computer program, which can be loaded into a memory device of a control data generation device (63) and/or a control device (61) for a device (4) for additive manufacturing are described.