3D Metal Printer Support Structure Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D metal object printers using metal drop ejection face inefficiencies in forming support structures, as the melted metal used for objects also forms strong bonds with support structures, requiring extensive cutting and machining to remove them, and the process of building pillars and connecting them laterally is time-consuming.
Innovation Solution
A method and apparatus where the ejector head of a 3D metal object printer operates to eject melted metal drops to form a first line of spatially separated pillars and then forms a continuous metal line over these pillars in a single pass, enhancing the speed and strength of support structure formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If melted metal is used to form both object features and support structures, then the support structures bond strongly with the object features, but extensive cutting, machining, and polishing is needed to remove the supports
Solution Approach 1:
The support structure is segmented into two distinct material components: a temporary support material (wax, polymer, or salt) that forms the initial support framework, and the final metal object material. This segmentation allows the temporary support to be easily removed after the metal object solidifies, while the metal object itself maintains its structural integrity and desired features.
2Ease of manufacture
If traditional pillar formation process is used, then support structures can be broken away more easily, but the process is time consuming due to thermal constraints
Solution Approach 1:
The ejection system operates continuously to form support walls and pillars in an uninterrupted sequence, eliminating the need for multiple passes and thermal cooling intervals. The system maintains optimal ejection parameters throughout the process, allowing rapid formation of complete support structures including foundations, walls, and pillar extensions in a single continuous operation.
Solution Approach 2:
The ejection system dynamically adjusts ejection parameters such as drop spacing, ejection frequency, and metal flow rate to optimize pillar formation speed and structural integrity. By controlling these parameters, the system can rapidly form closely-spaced pillars that maintain adequate strength while enabling faster production compared to traditional methods.
3Productivity
If melted metal drops are ejected too close to one another, then the heat of adjacent drops slows the freeze rate, but continuous firing is needed to join pillars and extend them efficiently
Solution Approach 1:
The ejection system optimizes drop spacing and ejection frequency parameters to achieve the ideal balance between formation speed and solidification rate. By precisely controlling these parameters, the system can ejection drops at optimal intervals that allow adequate heat dissipation and solidification while maintaining continuous operation to rapidly build support structures.
Solution Approach 2:
The ejection system employs periodic action with controlled intervals between drop ejections. This periodic ejection pattern allows each metal drop to solidify partially before the next drop is ejected, preventing excessive heat accumulation while maintaining high formation speed through continuous cyclic operation.
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 allows for the rapid creation of support structures with adequate strength for metal layers, reducing the need for extensive post-processing and improving the efficiency of the metal drop ejection process, enabling quicker and more efficient metal object manufacturing.
Implementation Method 1
An electrical current is passed through the coil to produce an electromagnetic field that causes a drop of melted metal at the nozzle of the receptacle to separate from the melted metal within the receptacle and be propelled from the nozzle
Implementation Method 2
the solid metal is fed into a heated receptacle of a vessel in the printer where the solid metal is melted
Data Source
AI summary
A metal object manufacturing apparatus is configured to eject melted metal drops to form a continuous metal line over a line of spatially separated pillars in a single pass. The ejection frequency for forming the continuous metal line is different than the frequency used to form the pillars. In one embodiment, the ejection frequency for forming the pillars is about 100 Hz and the frequency used to form the continuous metal line over the line of spatially separated pillars is about 300 Hz with a drop spacing of about 0.2 mm. Continuous metal lines are formed to extend the continuous metal lines over the pillars laterally to fill the gaps between the continuous metal lines over the pillars. These continuous metal lines that fill the gaps are formed while operating the ejection head at the 300 Hz frequency with a drop spacing of 0.28 mm.