3D Printed Component Holding Frame with Annular Gaps
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Solution Overview
Problem
Existing methods for forming three-dimensional components using loose particulate material often result in damage during handling due to direct grasping or support structures that allow movement, leading to potential damage from play and complex release mechanisms.
Innovation Solution
A method involving the formation of a holding frame with annular or sleeve-shaped holding spaces and sections, allowing the component to be supported indirectly via non-solidified particulate material in gaps, enabling safe and easy handling without play, and facilitating removal from the build box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an auxiliary frame is directly connected to the component with material bonds via thin webs, then the component can be supported during handling, but the release process becomes complex and still carries damage risk
Solution Approach 1:
The harmful material bonds between component and support structure are completely removed. Instead of using thin webs that require complex release, the invention uses a holding frame that engages with holding spaces on the component through form-fit connections, allowing the component to be supported without any material bonds that could cause damage during release.
Solution Approach 2:
The holding frame acts as an intermediary between the component and the handling system. It provides support and stability during handling through form-fit engagements, eliminating the need for direct material bonds between the component and support structures, thus simplifying the release process while maintaining component safety.
2Ease of operation
If the component is directly grasped for handling, then the handling process is simple, but the component is at risk of damage
Solution Approach 1:
The holding frame serves as a mediator between the handling system and the component. It can be easily grasped and manipulated, while its form-fit connections to the component provide secure support that prevents damage, combining handling simplicity with component protection.
Solution Approach 2:
The support function is segmented into the holding frame structure with multiple holding spaces and engagement features. This segmentation allows the frame to distribute support forces across multiple contact points, enhancing component protection while maintaining ease of handling through the frame's external geometry.
3Adaptability or versatility
If support structures allow small movements of the component, then flexibility is provided, but play causes potential damage to the component
Solution Approach 1:
The form-fit engagements between holding spaces and holding sections provide localized precision support at specific contact points, eliminating play and unwanted movements. This localized precision support protects the component from damage while the overall holding frame structure maintains adaptability for handling and positioning.
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 method allows for safe handling and reduced risk of damage by supporting the component without play, enabling easy removal of residual material and detachment from the holding frame, while maintaining structural integrity.
Implementation Method 1
The particle area printed with the binder sticks and solidifies due to the influence of the binder
Implementation Method 2
Selective consolidation of loose particulate material can also be accomplished using selective laser sintering
Implementation Method 3
Selective consolidation of loose particulate material can also be accomplished using selective electron beam sintering
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3C
AI summary
Method for forming a three-dimensional component (1) by successively selectively solidifying a loose particle material (PM) layer by layer, wherein a holding frame (3) is additionally formed during the formation of the three-dimensional component (1), wherein the holding frame (3) and/or the component (1) is formed with a plurality of holding spaces (5), each of which has a holding space wall (7) that substantially surrounds the holding space (5) in a ring-like manner, which defines an annular holding space inner contour (9) and a holding space opening (11), wherein a corresponding plurality of holding sections (13) formed on the component (1) and/or on the holding frame (3) with a holding section outer contour (15) engage in the holding spaces (5) via the associated holding space opening (11), wherein the respective holding section outer contour (15) is formed to be substantially conformal to the respective holding space inner contour (9),wherein the inner contour of the holding chamber (9) and the outer contour of the holding section (15) are each arranged at a small distance from each other, whereby an annular gap (17) is formed between the inner contour of the holding chamber (9) and the outer contour of the holding section (15), whereby unsolidified particle material (PM) outside the respective gap (17) is removed from the finished component (1), so that unsolidified particle material (PM) remains in contact with the inner contour of the holding chamber (9) and the outer contour of the holding section (15) in the respective gap (17), so that the component (1) remains supported without play on the holding frame (3) via the particle material (PM) remaining in the respective gap (17).