Modular Base Plate Segmentation for Additive Manufacturing Detachment
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Solution Overview
Problem
Existing layer-by-layer generative manufacturing methods require destructive processes to detach components from base plates, leading to material damage and inefficiencies, and support structures can cause thermal distortion issues.
Innovation Solution
A modular base plate composed of metal sheets with a flexible laminated core structure, allowing for easy detachment of components without damaging the base plate, and a screw connection system to generate a defined clamping force that compensates for local pressures during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a massive base plate is used for layer-by-layer generative manufacturing, then the component can be securely manufactured, but additional machines are required and the base plate cannot be reused, increasing loss of time and substance
Solution Approach 1:
The base plate is segmented into multiple individual sheets that can be separately removed. Each sheet forms a partial bearing surface, allowing the component to be detached in sections rather than requiring complete destruction or massive support structures. This segmentation enables reuse of the base plate while maintaining manufacturing reliability.
2Reliability
If a massive base plate is used for layer-by-layer generative manufacturing, then the component can be securely manufactured, but additional machines are required for detachment, increasing device complexity
Solution Approach 1:
The base plate is divided into multiple sheets that can be manually or easily removed. This eliminates the need for additional milling, eroding, or sawing machines, reducing device complexity while maintaining secure component manufacturing during the process.
3Reliability
If support structures are attached to the base plate, then the component can be securely held, but thermal distortion occurs and manual separation becomes impossible, worsening manufacturing precision and ease of operation
Solution Approach 1:
Instead of using massive support structures, the base plate is segmented into thin sheets that naturally minimize thermal mass and distortion. The segmented structure allows the component to be held securely during manufacturing while enabling easy manual separation after cooling, preventing thermal distortion issues.
Solution Approach 2:
The base plate transitions from a static massive structure to a dynamic segmented structure that can adapt during manufacturing. The individual sheets can be independently positioned and removed, providing flexibility that rigid support structures cannot achieve, thereby preventing thermal distortion and enabling easy separation.
4Reliability
If support structures are attached to the base plate, then the component can be securely held, but manual separation becomes impossible, worsening ease of operation
Solution Approach 1:
The base plate is divided into multiple thin sheets that can be easily peeled or removed by hand from the component. This segmentation maintains secure holding during manufacturing while enabling simple manual separation afterward, greatly improving ease of operation compared to massive support structures.
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 easy and damage-free detachment of components from the base plate, reduces material waste, and allows for multiple reuse of the base plate, thereby shortening cycle times and improving process reliability.
Implementation Method 1
the powder in each thin layer can be selectively solidified
Implementation Method 2
The powder is consolidated using a laser
Data Source
Figure 1~1b
Figure 2a~2b
Figure 3a~4
AI summary
The invention relates to a device (1) for the additive manufacturing of a component, in particular for the layer-by-layer additive manufacturing of a component (2), which is printed onto a base plate (4). The base plate (4) forms a bonding surface (17) for the application and compaction of powder to produce the component (2) and comprises several sheets (3), wherein the sheets (3) are shaped and arranged side by side such that the bonding surface (17) of the base plate (4) is formed by side surfaces (16) of the sheets (3). The invention further relates to methods using the device (1) wherein a sacrificial layer (21) and/or the component (2) are produced, and subsequently, the sheets (3) are individually separated from the sacrificial layer (21) or the component (2).