Disposable Support Structure for Additive Manufacturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Additive manufacturing of metal components often results in significant build stresses that can distort the components, and conventional support structures used to restrain distortion are costly and require removal through machining or manual methods.

Innovation Solution

A method involving the use of a disposable support structure with a protruding arrowhead or corrugated surface that maintains a 10-micron gap from the component during manufacturing, allowing for easy removal without fusion, and utilizing powder to transmit forces and minimize distortion, with heat treatment to relieve stresses after manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional support structures are used to restrain distortion during additive manufacture, then manufacturing precision is improved, but device complexity and cost increase due to the need for support structures that require machining or manual removal

Engineering Contradiction:

Improvecomponent distortion controlVSAvoidsupport structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The support structure is designed as a disposable component that is intentionally fused to the component during additive manufacture. After the component is manufactured and heat treated, the support structure is easily removed by breaking or snapping off, eliminating the need for complex machining or manual removal processes. This resolves the contradiction by using a simple, low-cost support structure that sacrifices itself during the manufacturing process.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The support structure and component are merged together through fusion during the additive manufacturing process. The support structure becomes an integral part of the component temporarily, allowing for easy removal after manufacturing without requiring separate support structures or complex removal mechanisms. This merging eliminates the need for complex support structure designs while maintaining distortion control during manufacturing.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If support structures are removed by machining or manual methods, then manufacturing precision is maintained, but productivity decreases due to additional removal steps

Engineering Contradiction:

Improvecomponent dimensional accuracyVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The support structure is designed as a disposable component that is easily broken or snapped off after the component is manufactured and heat treated. This eliminates the need for time-consuming machining or manual removal processes, significantly reducing the manufacturing cycle time while maintaining component dimensional accuracy. The support structure serves its purpose during manufacturing and is then discarded without requiring complex removal operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If support structures are designed to restrain distortion effectively, then manufacturing precision is improved, but ease of manufacture worsens due to the need for precise gap control to prevent fusion

Engineering Contradiction:

Improvecomponent distortion controlVSAvoidsupport structure fabrication

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The support structure and component are merged together through fusion during the additive manufacturing process. This eliminates the need for precise gap control between the support structure and component, as the fusion process naturally bonds them together. The support structure can be designed with simple geometries that are easily fabricated, and the fusion process ensures proper bonding without requiring tight tolerances or complex positioning mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 effectively reduces distortion and eliminates the need for costly machining steps by ensuring the support structure can be easily removed, while maintaining sufficient force transfer to minimize component distortion, and heat treatment relieves built-up stresses, allowing for efficient production.

Implementation Method 1

melting and fusing powder in layers from a build plate to form the component and a disposable support structure

Methodology Applied

Scientific EffectMelting and fusing: Melting

Implementation Method 2

heat treating the component

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 3

a stress relieving heat treatment cycle has been performed

Methodology Applied

Scientific EffectStress relieving: Stress Relaxation

Data Source

PatentUS20240051026A1Method of manufacturing a component

Publication Date: 2024.02.15 ROLLS ROYCE PLC

AI summary

There is disclosed a method of manufacturing a component. The method comprises melting and fusing powder in layers from a build plate to form the component and a disposable support structure, heat treating the component; and removing the support structure. Each layer of the support structure and the component are formed such that there is at least a 10-micron gap between them, to ensure that the component and the support structure are not fused together.