Dynamic Support Member for 3D Printing Overhangs

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Solution Overview

Problem

In 3D printing, unsupported portions of a part often require additional support material to prevent sagging, leading to material waste, increased printing time, and costs due to the need for support material that must be printed and later removed.

Innovation Solution

A dynamically adjustable support member system that moves from a retracted position to a support position during the printing process to support overhanging portions of the part, reducing the need for additional support material by providing structural support only when necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If support material is printed underneath unsupported portions to prevent sagging, then structural strength of the part is improved, but material waste increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmaterial waste

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent applies a dynamically adjustable support member that can move between a retracted position (when not needed) and a support position (when needed). This dynamic adjustment allows the support structure to be deployed only when required to prevent sagging in overhanging portions, thereby maintaining structural strength while minimizing material waste by avoiding unnecessary support material in regions where it is not needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The support member is positioned locally at specific locations where overhanging portions require support. By using a dynamically adjustable mechanism, the support is applied only to the specific local areas needing it, rather than providing uniform support throughout the entire print bed. This localized approach ensures structural strength where needed while reducing material waste in areas where support is not required.

Inventive Principle:

Principle #3Local quality

2Strength

If support material is printed and removed after printing, then structural integrity during printing is improved, but printing time increases

Engineering Contradiction:

Improvestructural integrityVSAvoidprinting time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The dynamically adjustable support member allows the support structure to be deployed only when needed during the printing process. By moving from a retracted position to a support position at the appropriate moment, the system provides structural integrity to overhanging portions without requiring the printing of extensive support material that would need to be removed later, thereby reducing overall printing time.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent extracts the support function from the traditional support material approach. Instead of printing and removing support material, the system uses a physically adjustable support member that can be positioned and held in place, eliminating the need for the time-consuming process of printing and subsequent removal of support structures.

Inventive Principle:

Principle #2Taking out (Extraction)

3Stability of the object's composition

If support material is used for overhanging portions, then sagging prevention is improved, but costs increase

Engineering Contradiction:

Improvesagging preventionVSAvoidcosts

Core Design Contradiction:

Stability of the object's compositionVSLoss of substance

Solution Approach 1:

The dynamically adjustable support member provides sagging prevention only when and where needed. By moving from a retracted to a support position based on the printing progress and geometric requirements, the system prevents sagging in overhanging portions while avoiding the cost of printing and removing unnecessary support material, thereby reducing overall costs.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The support member is designed as a simple, inexpensive component that can be easily adjusted and repositioned. Rather than using expensive support material that must be printed and removed, the system employs this affordable, reusable support member that provides the necessary sagging prevention without the associated costs of material waste and post-processing.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS11123925B2Methods for making 3D printed parts using a dynamic build platform and 3D printed parts formed therefrom

Publication Date: 2021.09.21 FORD MOTOR CO

AI summary

A method of 3D printing a part with an overhanging portion requiring support during printing is provided. The method includes moving a dynamically adjustable support member to support the overhanging portion during printing of the part. The dynamically adjustable support member may be moved from a retracted position to a support position after a first portion of the part is printed and the overhanging portion may be supported by the dynamically adjustable support member in the support position. The part may be printed in a 3D printing chamber with a base and at least one wall. The base may have a first dynamically adjustable support member and the at least one wall may have a second dynamically adjustable support member. A first overhanging portion and a second overhanging portion of the part may be printed over the first dynamically adjustable support member the second dynamically adjustable support member, respectively.