Constricted Support Members for Warpage Control in 3D Metal Printing
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Solution Overview
Problem
The existing manufacturing methods for three-dimensional molded objects using lamination molding techniques often result in warpage due to residual stress, which reduces dimensional precision, increases material usage, and elevates manufacturing costs, as the sintered layers shrink and are fixed to a base plate, leading to tension stress and subsequent warping upon release.
Innovation Solution
A lamination molding apparatus and method that includes a recoater head for uniform powder distribution, a laser light irradiation device for forming sintered layers, and a control device that forms a base part with constricted support members and a main body part, allowing for controlled stress release through crack generation in the base part, thereby reducing warpage by managing residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If sintered layers are fixed to a base plate during lamination molding, then the sintered layers can be supported and positioned stably, but residual stress accumulates causing warpage in the final molded object
Solution Approach 1:
The patent introduces support members with constricted central portions before completing the lamination molding process. These support members are strategically positioned to provide temporary support during sintering, and are designed to be removed afterward. This preliminary support structure allows the sintered layers to maintain stability during the critical sintering phase while preventing excessive residual stress accumulation that would cause warpage.
Solution Approach 2:
The support structure is segmented into multiple discrete support members rather than a continuous base plate attachment. Each support member has a constricted central portion that provides localized support. This segmentation allows stress to be distributed and managed more effectively, preventing the accumulation of uniform residual stress across the entire sintered layer that would lead to warpage.
2Manufacturing precision
If allowance is increased to compensate for warpage, then the final product precision can be achieved after secondary processing, but material usage and processing time increase
Solution Approach 1:
The support members with constricted central portions are introduced in advance to prevent warpage during the lamination molding process itself. By addressing the root cause of dimensional inaccuracies during manufacturing rather than compensating for them afterward, the need for excessive allowance and subsequent material removal in secondary processing is eliminated, thereby reducing both material usage and processing time.
3Manufacturing precision
If support members with constricted central portions are arranged continuously in the base part, then stress can be controlled and warpage reduced, but the device complexity increases
Solution Approach 1:
The support members feature constricted central portions that create localized variations in the support structure. This local quality change allows the support members to provide adequate support while creating controlled stress distribution patterns. The constricted portions act as stress relief zones, allowing the overall structure to maintain simplicity while achieving effective warpage control through localized structural modifications.
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 approach effectively minimizes warpage in three-dimensional molded objects, enhancing precision and reducing material usage and processing time, leading to lower manufacturing costs by allowing for stable support and controlled stress distribution within the sintered body.
Implementation Method 1
a laser light irradiation device that irradiates the material powder layer with laser light, and heats and melts the material powder to form a sintered layer
Implementation Method 2
The sintered layer shrinks when the material powder being heated and melted is cooled and solidified to form the sintered layer
Data Source
AI summary
A lamination molding apparatus of the present disclosure includes: a recoater head that forms a material powder layer by uniformly spreading metal material powder on a modeling table at a predetermined height; a laser light irradiation device that irradiates the material powder layer with laser light, and heats and melts the material powder to form a sintered layer; and a control device that forms a sintered body, which is an three-dimensional molded object, by repeatedly driving and controlling the recoater head and the laser light irradiation device; the control device reads sintered body data, that is configured by the shape of a base part in which at least a plurality of support members with constricted central portion are arranged continuously and the shape of a main body part which is a final molded product, and drives and controls the laser light irradiation device and the recoater head to form the sintered body.