Non-Contact Support for Acute Angle DMLS Components
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Solution Overview
Problem
Direct metal laser sintering (DMLS) additive manufacturing faces challenges when constructing components with 'unfriendly' angles, such as acute angles, as the recoater blade may damage the component or fail to reach without damaging the recoater blade, requiring adjustments in orientation or build time.
Innovation Solution
An additively manufactured non-contact support is created adjacent to the edge of the component, with a contoured surface that allows the recoater blade to pass smoothly, preventing damage and enabling the construction of components with acute angles by maintaining the component's original orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the recoater blade is used to construct components with acute angles, then the component geometry can be created, but the recoater blade may damage the component or be damaged itself
Solution Approach 1:
A non-contact support structure is additively manufactured alongside the component before the recoating process begins. This support extends into the acute angle region, providing preliminary protection to the component geometry before the recoater blade passes through, preventing direct contact between the blade and the vulnerable acute angle surfaces.
Solution Approach 2:
The non-contact support acts as an intermediary element between the recoater blade and the component's acute angle geometry. It provides a protective barrier that allows the blade to pass through the build volume without directly contacting or damaging the component's vulnerable surfaces, while the support itself is designed to be removable after manufacturing.
2Reliability
If the component orientation is adjusted to avoid acute angles facing the recoater blade, then the recoater blade damage is prevented, but the component properties are compromised
Solution Approach 1:
The non-contact support is manufactured in advance alongside the component, allowing the component to be built in its optimal orientation without needing to reorient it to avoid acute angles. The support is already in place before recoating begins, providing protection while maintaining the component's desired geometry and properties.
Solution Approach 2:
The support structure serves as a mediator that enables the component to maintain its optimal manufacturing orientation and properties while still protecting against recoater blade damage. It allows the acute angle geometry to face the recoater blade without compromising component quality, as the support absorbs the protective function.
3Reliability
If the surface is extruded down to the build plate to create suitable orientation, then the recoater blade can pass safely, but other component properties are sacrificed
Solution Approach 1:
Instead of modifying the component's surface geometry by extruding it down to the build plate, a non-contact support is manufactured in advance to provide the necessary protection. This preserves the component's original surface geometry and design intent while still enabling safe recoater blade passage.
Solution Approach 2:
The non-contact support acts as an intermediary that provides recoater blade protection without requiring modification of the component's surface geometry. It maintains the acute angle surfaces in their original, functionally-optimal positions while the support structure handles the protective function during manufacturing.
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 solution allows for the successful construction of components with acute angles without damaging the recoater blade or the component, reducing build time and maintaining the component's properties, thereby expanding the range of geometries that can be manufactured.
Implementation Method 1
Direct metal laser sintering (DMLS) is an additive manufacturing technique in which a laser is utilized to sinter powdered material. The laser may be guided by a 3D model to bind the powdered material and grow a solid structure component.
Data Source
AI summary
An additively manufactured assembly including an additively manufactured component with an edge oriented with respect to a recoater blade direction and an non-contact support that does not form a part of the additively manufactured component, the additively manufactured support located adjacent the edge. A method of additively manufacturing a component includes additively manufacturing an component with an edge oriented with respect to a recoater blade direction simultaneous with additively manufacturing an non-contact support that does not form a part of the component, the additively manufactured support located adjacent the edge.