Porous Intermediate Assembly for Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing methods for metal parts are limited in designing parts with overhang surfaces greater than 45° due to insufficient support during layer stacking, requiring additional support structures that need manual removal after manufacturing.

Innovation Solution

An intermediate assembly for additive manufacturing includes a support structure with a fusible, porous connecting portion, a baseplate with channels, and a column, allowing for the manufacture of parts with overhang surfaces exceeding 45°, and enabling easy removal of the support structure through chemical dissolution and mechanical rupture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If support structures are added to enable overhang surfaces greater than 45°, then manufacturing capability is improved, but device complexity and manual labor increase

Engineering Contradiction:

Improvemanufacturing capability for overhang surfacesVSAvoidsupport structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The connecting portion of the support structure is made porous with controlled porosity (30-70%), allowing chemical solutions to penetrate and dissolve the support material after manufacturing. This porous structure enables automatic support removal without manual intervention, resolving the contradiction by maintaining manufacturing capability while reducing manual labor and simplifying the overall process

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The support structure utilizes parameter changes in material properties through chemical dissolution. The connecting portion is designed with specific porosity parameters that allow it to be selectively dissolved by chemical solutions after manufacturing, automatically removing the support structure without requiring manual intervention or complex removal mechanisms

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If manual removal of support structures is performed, then manufacturing precision is maintained, but loss of time and productivity decrease

Engineering Contradiction:

Improvepart geometry accuracyVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The manual mechanical removal process is replaced with a chemical dissolution system. Chemical solutions automatically penetrate the porous connecting portion and dissolve the support structure, eliminating the need for manual machining operations while maintaining manufacturing precision and significantly reducing cycle time

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The support structure is designed to self-remove through chemical dissolution. The porous connecting portion automatically dissolves when exposed to chemical solutions, eliminating the need for external manual intervention and enabling automatic support removal that maintains precision while improving productivity

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If porous connecting portion is used for support structure removal, then ease of manufacture is improved, but loss of substance increases

Engineering Contradiction:

Improvesupport structure removal easeVSAvoidmaterial dissolution

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The porous structure and chemical dissolution are applied locally only to the connecting portion of the support structure, not the entire part. This localized approach enables easy removal of supports while minimizing material loss, as the chemical solution only affects the designated support areas with controlled porosity

Inventive Principle:

Principle #3Local quality

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 enables the manufacturing of metal parts with complex geometries, including overhang surfaces greater than 45°, without the need for post-manufacturing machining steps, improving design flexibility and reducing manual labor in removing support structures.

Implementation Method 1

The connecting portion (38) has a porosity which is greater than or equal to 30%, and greater than or equal to 40%, and greater than or equal to 50%, and greater than or equal to 60%, and greater than or equal to 70%

Methodology Applied

Scientific EffectPorosity: Porosity

Implementation Method 2

immersion of the intermediate assembly in a dissolution solution, and dissolution of an outer surface of the intermediate assembly

Methodology Applied

Scientific EffectChemical dissolution:

Implementation Method 3

manufacturing at least one part, in particular one or more metal part(s), by melting successive layers of powder by means of a laser beam

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 4

melting successive layers of powder by means of a laser beam

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20250144711A1Intermediate assembly for additive manufacturing

Publication Date: 2025.05.08 SAFRAN ADDITIVE MFG CAMPUS

AI summary

An intermediate assembly for additive manufacturing includes a metal part with an overhang portion. The intermediate assembly further includes a support structure for the overhang portion, wherein the support structure includes a fusible, porous connecting portion extending from the overhang portion, a baseplate extending from the connecting portion and defining a plurality of channels, and at least one column carrying the baseplate.