Particle-Based Sintering Supports for Additive Manufacturing
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Solution Overview
Problem
Additive manufacturing of three-dimensional objects faces challenges in supporting dense and heavy model materials during processing, which can lead to deformation, sagging, slumping, breaking, cracking, or warping due to gravity, especially for objects with cantilevered portions, gaps, and overhangs.
Innovation Solution
The use of particle-based supports, such as ceramic or metal particles with higher melting temperatures, that are added around the object to provide temporary support during heating, which can compress, evaporate, or crumble at specific temperatures to prevent stress and strain, allowing the object to maintain its shape and internal strength without inducing deformation or damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If particle-based supports are added around the object to provide temporary support during heating, then the object maintains its shape and structural integrity, but the device complexity increases due to the need for support addition and removal mechanisms
Solution Approach 1:
The patent uses particle-based supports that are temporary and disposable, designed to be added around the object during heating and then easily removed afterward. These supports provide necessary structural integrity during the heating process but are not meant to remain in the final product, reducing the need for complex permanent support structures.
Solution Approach 2:
The particle-based supports undergo parameter changes during the heating process, transitioning from a solid particulate state that provides mechanical support to a state where they can be easily removed. The supports are designed to withstand the heating temperature and then be removed through methods such as vibration, gas flow, or mechanical agitation.
2Shape
If particle-based supports are used to support cantilevered portions, gaps, overhangs, and unsupported ranges, then deformation and sagging are prevented, but the manufacturing precision requirements increase for proper support placement and removal
Solution Approach 1:
The particle-based supports are applied locally to specific areas of the object that require support, such as cantilevered portions, gaps, overhangs, and unsupported ranges. Rather than requiring uniform support throughout the entire object, the particulate supports are concentrated in the critical areas where deformation and sagging are most likely to occur.
Solution Approach 2:
The support function is segmented into discrete particle-based units that can be independently distributed and removed. This segmentation allows for flexible placement of supports in specific locations without requiring a monolithic support structure, and enables easier removal of supports after they have served their purpose.
3Loss of substance
If the particle-based support is removed after heating, then the final object is obtained without support interference, but the removal process may cause cracking or warping if not done properly
Solution Approach 1:
The particle-based supports are designed to be easily removable after the heating process, with preliminary considerations made for the removal method. The supports are selected and positioned such that they can be removed through gentle means such as vibration, gas flow, or mechanical agitation without causing damage to the now-cooled and solidified object.
Solution Approach 2:
The particle-based supports are extracted from the final object after serving their temporary support function. The removal process is designed to separate the supports from the object without causing cracking or warping, using methods such as vibration, gas flow, or mechanical agitation that apply minimal stress to the object.
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 particle-based supports effectively prevent deformation and damage by providing structural integrity until the object achieves sufficient internal strength, allowing for the formation of complex shapes without sagging or slumping, and can be easily removed once the object is sintered, reducing the risk of cracking or warping.
Implementation Method 1
fluidizing the particle-based support around the part such that the particle-based support provides a buoyant force to the part
Implementation Method 2
The particle-based support may be characterized by a compressive force that prevents part deformation, sagging, slumping, breaking, cracking, or warping
Implementation Method 3
which can compress, evaporate, or crumble at specific temperatures
Implementation Method 4
Heating to the first temperature may result in the evaporation of the particle-based support. In some aspects, heating to the first temperature may result in the sublimation of the particle-based support.
Data Source
AI summary
Systems, apparatus and methods of additively manufacturing objects are disclosed. Specifically, provided herein are methods of heating objects having a particle-based support at least partially surrounding the object during portions of stages of the heating. Additionally, systems, apparatus, and methods for removing the particle-based support during heating, such that the object can continue heating to form a final part. Systems, apparatus, and methods for distributing the particle-based support to shore the objects through heating are disclosed. Systems, apparatus, and methods for removing the particle-based support are also disclosed herein.