Laminated Metal Part Supports for Accurate Build and Easy Removal
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Solution Overview
Problem
Existing additive manufacturing processes for metal parts face challenges in maintaining dimensional accuracy and preventing distortion due to high forces and gravity, requiring complex support structures that are difficult to remove without causing further deformation.
Innovation Solution
The method involves depositing foil layers with integrated support regions that evenly distribute temperature and pressure, using inhibitory materials and connection bridges to stabilize the object, and employing selective inhibition strategies to facilitate easy removal of support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional support structures are used in metal sintering processes, then distortion prevention is achieved, but support removal becomes difficult and may cause further distortion
Solution Approach 1:
The support structure is divided into multiple discrete support regions rather than a continuous mass, allowing individual supports to be selectively removed or broken away after sintering, reducing the difficulty of support removal while maintaining stability during the process
Solution Approach 2:
Different regions of the support structure have different properties - the support regions provide stability during sintering while being designed with different removal characteristics than the object regions, enabling easy post-process removal without damaging the final part
2Adaptability or versatility
If comprehensive support strategy is implemented, then manufacturing complexity increases, but more complex parts can be manufactured with fewer design rules
Solution Approach 1:
The support generation strategy is designed to be universally applicable across different part geometries and complexities, using the same fundamental approach of depositing support regions with foil layers rather than requiring custom support designs for each part type
Solution Approach 2:
Support regions are pre-planned and deposited during the additive manufacturing process itself, rather than adding supports afterward, which simplifies the overall manufacturing workflow and enables complex parts to be built with integrated support from the outset
3Manufacturing precision
If support structures are used to counteract gravity and friction forces, then dimensional accuracy is maintained, but uniform pressure and heat distribution is compromised
Solution Approach 1:
The support structure is segmented into discrete regions that can be optimized for both mechanical support function and thermal conduction, allowing heat to distribute more uniformly through the object while still providing necessary gravitational and frictional counteraction
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 enables the fabrication of complex metal geometries with improved dimensional accuracy and structural integrity, reducing object-processing time and cost by allowing for easier removal of support structures.
Implementation Method 1
the second foil layer is spot welded onto the first foil layer
Implementation Method 2
depositing an inhibitory material including carbon onto at least one of the first foil layer or the second foil layer
Data Source
AI summary
A method for the additive manufacturing of an object and a system for manufacturing an object. The method includes depositing a first foil layer, the first foil layer including a first body section, a first support section connected to the first body section, and a second support section connected to the first body section; depositing a second foil layer, the second foil layer comprising a second body section, a third support section, and a fourth support section; aligning the second foil layer and the first foil layer; and applying at least one of heat and pressure to the first foil layer and the second foil layer to form the object comprising the first body section and the second body section.