Pin Array Sintering Supports for 3D Printed Metal Parts
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Solution Overview
Problem
3D binder jetting printers face challenges in maintaining the structural integrity and preventing deformation of 3D printed metal objects during the sintering process, as the 'green' parts shrink and lose density, leading to potential deformation and loss of shape.
Innovation Solution
A reusable support device featuring a pin array with high melting point pins that can be adjusted to conform to the shape of the object, using mechanisms like springs or actuators to maintain support as the object shrinks, and optionally a thermally responsive material bed to adjust the pin array's configuration during sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the green part is placed on a flat support surface during sintering, then the setup is simple, but the part deforms and loses its shape due to shrinkage
Solution Approach 1:
The support surface is segmented into multiple individual pins arranged in an array, allowing each pin to independently support different regions of the part. This segmentation enables the support structure to adapt to local shrinkage variations across the part surface while maintaining overall structural integrity during sintering.
Solution Approach 2:
The pin array is designed to be adjustable rather than fixed, allowing the pins to be repositioned or reconfigured during the sintering process. This dynamic adjustment capability enables the support structure to accommodate the part's shrinkage and maintain contact with the part surface, preventing deformation while preserving shape accuracy.
2Stability of the object's composition
If a fixed support structure is used during sintering, then the structure is simple and stable, but it cannot adapt to the shrinking part causing deformation
Solution Approach 1:
The pin array transitions from a static fixed structure to a dynamic adjustable system. The pins can be individually repositioned or the entire array can be reconfigured during sintering to match the part's changing dimensions, providing both stability during each sintering stage and adaptability to overall shrinkage.
Solution Approach 2:
The support structure's geometric parameters (pin positions, spacing, heights) are made changeable during the sintering process. By adjusting these parameters to match the part's shrinkage pattern, the structure maintains both stability for support and adaptability to dimensional changes, preventing deformation.
3Productivity
If a reusable support device is implemented, then productivity increases through multiple uses, but the device complexity increases
Solution Approach 1:
The support device is segmented into modular pin elements that can be independently adjusted or replaced. This modularity simplifies the adjustment mechanism for each individual pin while allowing the entire array to be reconfigured for different parts, enhancing reusability without requiring complex integrated control systems.
Solution Approach 2:
The pin array is designed with universal adjustability to support various part geometries and sizes. By making the support structure multi-functional through adjustable pin configurations, a single device can serve multiple sintering applications, increasing productivity and justifying the added complexity through versatile reuse.
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 support device effectively prevents deformation by adjusting to the object's shrinking shape, ensuring precise final form and allowing for multiple reuse, while the high melting point materials withstand the high temperatures involved in the sintering process.
Implementation Method 1
The support includes a pin array with high melting point pins such as ceramic pins
Implementation Method 2
each of the pins may be supported by a spring that allows the pins to rise or fall in response to the shifting weight applied by the object
Implementation Method 3
The green part may be removed from the printer and processed in a sintering furnace to fuse or sinter the metal powder to produce a generally highly dense metal part
Data Source
AI summary
Techniques for using a pin array to support a 3D printed object during sintering are disclosed. An example method includes adjusting pins of a pin array to provide support for a bottom surface of the 3D printed object, and placing the 3D printed object on the pin array. The method also includes placing the 3D printed object and pin array in a sintering oven, and heating the 3D printed object in the sintering oven to sinter the 3D printed object while being supported by the pin array.