Grown Build Envelope Support for Large-Scale Powder Bed Printing
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Solution Overview
Problem
Conventional additive manufacturing systems face limitations in building large objects due to weight and control issues with powder, requiring significant supports that consume time and energy, and are difficult to manage for uniform layer formation.
Innovation Solution
A method involving a dynamically grown build envelope that retains unfused powder and supports the object with a structure extending from its inner surface, allowing for larger object sizes and reduced resource usage by minimizing standalone support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional additive manufacturing systems use powder bed fusion with build platforms, then objects can be fabricated layer by layer, but the systems face weight and control issues with powder and require significant support structures that consume time and energy
Solution Approach 1:
The support function is segmented between the build envelope and standalone support structures. The build envelope provides primary support for overhanging portions, while standalone support structures provide supplemental support only where needed, dividing the support function into multiple components that can be optimized independently
Solution Approach 2:
The build envelope serves dual functions: containing the powder material and providing structural support for the object being fabricated. By making the envelope itself load-bearing, the system eliminates the need for separate, extensive support structures, allowing the system to support itself
2Shape
If significant support structures are used to hold overhanging portions, then objects can be built with complex geometries, but time and energy are consumed and support structures are difficult to manage for uniform layer formation
Solution Approach 1:
The build envelope performs multiple functions simultaneously: it contains the powder material, provides structural support for overhanging portions, and defines the build volume. This multi-functionality eliminates the need for separate support structures, reducing fabrication time and energy consumption while maintaining geometric complexity
3Reliability
If standalone support structures are used to support overhanging portions, then objects can be built, but the support structures consume resources and are difficult to manage
Solution Approach 1:
The support function is merged into the build envelope structure itself. The envelope walls provide direct support for overhanging portions, combining the containment and support functions into a single integrated structure, thereby eliminating waste associated with separate support structures
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 the creation of large-scale additively manufactured objects with reduced waste and energy consumption by dynamically forming a build envelope that supports the object, allowing for more efficient and precise construction of complex shapes.
Implementation Method 1
irradiating a layer of powder in a build area above a build platform to form a fused region
Implementation Method 2
The energy beam sinters or melts a cross sectional layer of the object being built
Data Source
AI summary
The present disclosure generally relates to additive manufacturing systems and methods on a large-scale format. One aspect involves a method for fabricating an object. The method includes (a) irradiating a layer of powder in a build area above a build platform to form a fused region; (b) providing a subsequent layer of powder over the build area; (c) repeating steps (a) and (b) until at least a portion of the object, a support structure, and a build envelope are formed; and (d) removing the object from the build envelope and the support structure. The support structure extends from an inner surface of the build envelope to a location proximate a location of the object to be built.