Metal Drop 3D Printing Support Structures With Controlled Oxidation
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Solution Overview
Problem
Metal drop ejecting 3D printers face challenges in forming support structures that do not adhere tightly to object features, requiring significant machining and polishing for removal, and coordinating different metals for support structures can damage the object due to thermal conditions.
Innovation Solution
A method involving an inert gas supply around melted metal drops and controller-generated instructions to increase oxidation of ejected metal drops, forming support structures that do not strongly adhere to object features, allowing for easy separation without machining, using a 3D metal object printer with an ejector head, heater, and platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If melted metal is used to form support structures, then the support structures bond strongly with object features, but significant machining and polishing is needed to remove the supports
Solution Approach 1:
The patent applies different surface qualities to different parts of the metal drops. The portion contacting the object feature maintains a clean, non-oxidized surface for strong bonding, while the portion exposed to oxidizing atmosphere develops an oxide layer that prevents adhesion to the support structure, enabling easy removal.
Solution Approach 2:
The patent changes the oxidation state parameter of the metal drops by exposing them to an oxidizing atmosphere (oxygen or oxygen-containing gas) during ejection and formation. This creates regions of different oxide concentration that differentiate the bonding behavior of different surfaces.
2Ease of manufacture
If a different metal is used for support structures, then the supports can be easily removed, but coordinating thermal conditions for different metals is difficult and can damage the object
Solution Approach 1:
The patent uses the same metal material for both the object features and the support structures. This eliminates the need to coordinate different thermal conditions for different metals, simplifying the manufacturing process while still enabling easy support removal through controlled oxidation.
3Manufacturing precision
If inert gas is supplied around melted metal drops, then oxidation is prevented and clean metal surfaces are formed, but support structures will adhere tightly to object features
Solution Approach 1:
The patent creates local quality differences in the metal drops by controlling oxide distribution. The inert gas protects the portion contacting the object feature from oxidation, while allowing oxidation on the portion forming the support structure interface, creating different surface properties in different locations.
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 formation of support structures that can be easily separated from metal objects without damaging them, maintaining the printer environment and reducing post-manufacture processing needs.
Implementation Method 1
generating machine-ready instructions that increase oxidation of ejected melted metal drops after the melted metal drops have been ejected from the receptacle within the ejector head
Implementation Method 2
a heater configured to heat the vessel while the vessel is in the ejector head to a temperature sufficient to melt solid metal within the receptacle of the vessel
Implementation Method 3
An electrical current is passed through the coil to produce an electromagnetic field that causes the meniscus of the melted metal at a nozzle of the receptacle to separate from the melted metal within the receptacle and be propelled from the nozzle
Data Source
AI summary
A three-dimensional (3D) metal object manufacturing apparatus is configured to increase the oxidation of ejected melted metal drops for the formation of metal support structures during manufacture of a metal object with the apparatus. The oxidation can be increased by either increasing a distance between the ejector head and a platform supporting the metal object or by providing an air flow transverse to the direction of movement of the melted metal drops, or both.