Fracturable Interface for Additive Manufacturing Support Removal
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Solution Overview
Problem
Existing support structures in additive manufacturing, particularly in metal printing, are difficult to remove and can degrade the quality of the final printed part surface, requiring significant time and resources for post-processing.
Innovation Solution
Incorporating a fracturable interface using a native non-metal, such as a native oxide, nitride, or oxynitride, at the interface between the article and the support structure, which allows for easy removal of the support structures by creating a fracture zone without compromising thermal management or structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional support structures are used in metal additive manufacturing, then structural stability and thermal management are improved, but removal difficulty and post-processing time increase
Solution Approach 1:
The support structure is segmented into two distinct materials: a metal support structure providing structural stability and a fracturable interface layer enabling easy removal. This segmentation allows each material to perform its specific function optimally while resolving the contradiction between maintaining structural integrity and enabling easy removal.
Solution Approach 2:
A fracturable interface layer composed of a different material than the support structure and part is introduced as an intermediary between them. This intermediate layer is specifically designed to fracture easily during removal, eliminating the time-consuming mechanical cutting process while maintaining the structural stability provided by the metal support structure.
2Reliability
If traditional support structures are used in metal additive manufacturing, then structural stability is improved, but surface quality degradation occurs
Solution Approach 1:
The support structure is segmented into a metal support structure and a separate fracturable interface layer. This segmentation allows the metal structure to provide structural stability while the interface layer can be easily removed without leaving debris on the part surface, thus maintaining surface quality.
Solution Approach 2:
The fracturable interface layer acts as an intermediary that prevents direct contact between the support structure and the part surface. This intermediate layer can be cleanly fractured and removed, avoiding the surface quality degradation that would occur with traditional direct-contact support structures requiring mechanical removal.
3Temperature
If traditional support structures are used in metal additive manufacturing, then thermal management is improved, but removal difficulty increases
Solution Approach 1:
The support structure is segmented into a metal support structure that provides thermal management and a separate fracturable interface layer that enables easy removal. The metal layer maintains thermal conductivity for heat dissipation, while the interface layer is designed to fracture easily, resolving the contradiction between thermal management and removal ease.
Solution Approach 2:
The fracturable interface layer serves as an intermediary between the metal support structure and the part. This intermediate layer can be easily fractured and removed without affecting the thermal management capabilities of the metal support structure, thus resolving the contradiction between maintaining thermal management and improving removal ease.
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
Enables efficient removal of support structures without mechanical cutting, improving the surface quality and reducing post-processing time and costs, while maintaining thermal conduction properties.
Implementation Method 1
the fracturable material being formed by exposing portions of metal in at least one form chosen from the droplets, the additional droplets, the first layer and the addition layer with a gas reactant
Data Source
AI summary
An embodiment of the present disclosure is directed to a method of additive manufacturing. The method comprises: i) forming a first layer, the first layer comprising at least one material chosen from an article material, a support structure material and a fracturable material; ii) forming an additional layer on the first layer, the additional layer comprising at least one material chosen from the article material, the support structure material and the fracturable material; and iii) repeating ii) one or more times to form a three-dimensional build comprising an article and at least one support structure attached to the article at an interface, the interface comprising the fracturable material formed during one or more of i), ii) or iii), the fracturable material being formed by exposing a print material with a gas reactant. A three-dimensional build is also disclosed.