Lattice Support Structures for Powder Bed Fusion Warping Control
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Solution Overview
Problem
Existing additive manufacturing methods using powder bed fusion systems face issues with residual stresses causing warping or breakage of components and build platforms due to large temperature gradients, leading to system malfunctions, and larger support structures require excessive time and energy for removal.
Innovation Solution
The use of lattice support structures with a plurality of support members arranged in a lattice configuration, designed using polygon-based imaging software, which facilitates secure component attachment and efficient heat dissipation, allowing for rapid and secure manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger support structures are provided to supply increased holding strength, then the holding strength between component and support structure is improved, but the build platform may warp when cooling due to significant heat conduction, and more time and energy are required for removal during post fabrication processes
Solution Approach 1:
The support structure is segmented into a lattice configuration with multiple interconnected members forming a three-dimensional framework. This segmentation provides sufficient holding strength through distributed contact surfaces while reducing the overall material volume compared to solid support structures, thereby decreasing removal time and energy requirements.
Solution Approach 2:
The support structure utilizes a lattice configuration that creates a porous, open-cell framework. This porous structure reduces thermal mass and heat conduction to the build platform while maintaining structural integrity and holding strength through the geometric arrangement of lattice members.
2Strength
If larger support structures are provided to supply increased holding strength, then the holding strength between component and support structure is improved, but larger support structures require more time and energy to remove relative to smaller support structures during post fabrication processes
Solution Approach 1:
The support structure is segmented into a lattice configuration with multiple interconnected members forming a three-dimensional framework. This segmentation provides sufficient holding strength through distributed contact surfaces while reducing the overall material volume compared to solid support structures, thereby decreasing removal time and energy requirements.
Solution Approach 2:
The support structure utilizes a lattice configuration that creates a porous, open-cell framework. This porous structure reduces thermal mass and heat conduction to the build platform while maintaining structural integrity and holding strength through the geometric arrangement of lattice members.
3Loss of time
If smaller support structures are used, then removal time and energy are reduced, but holding strength is decreased and likelihood of component breaking away increases
Solution Approach 1:
The support structure is segmented into a lattice configuration with multiple interconnected members forming a three-dimensional framework. This segmentation provides sufficient holding strength through distributed contact surfaces while reducing the overall material volume compared to solid support structures, thereby decreasing removal time and energy requirements.
Solution Approach 2:
The support structure transitions from traditional two-dimensional planar supports to a three-dimensional lattice framework. This dimensional change enables the structure to provide holding strength through volumetric distribution of support members, achieving high strength-to-volume ratio that reduces both removal time and material consumption.
4Strength
If larger support structures are used, then holding strength is improved, but heat conduction to the build platform increases causing warping
Solution Approach 1:
The support structure utilizes a lattice configuration that creates a porous, open-cell framework. This porous structure reduces thermal mass and heat conduction to the build platform while maintaining structural integrity and holding strength through the geometric arrangement of lattice members.
Solution Approach 2:
The support structure is segmented into a lattice configuration with multiple interconnected members forming a three-dimensional framework. This segmentation provides sufficient holding strength through distributed contact surfaces while reducing the overall material volume compared to solid support structures, thereby decreasing removal time and energy requirements.
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 lattice support structures provide enhanced stability and thermal conductivity, reducing warping and breakage risks while enabling faster and more efficient post-fabrication removal processes.
Implementation Method 1
provide a thermally conductive pathway for heat to dissipate from the component
Data Source
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AI summary
A method for additively manufacturing a component includes generating, via imaging software, a plurality of slices of a support structure of the component based on component geometry. The method also includes melting or fusing, via the additive manufacturing system, layers of material to a build platform of the component so as to form the support structure according to the plurality of slices. The support structure includes a lattice configuration having of a plurality of support members arranged together to form a plurality of cells. Further, the method includes melting or fusing, via the additive manufacturing system, a component body to the support structure. After the component body solidifies, the method includes removing all of the support structure from the component body to form the component.