Powder-Bed Component Gaps to Replace AM Support Structures
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Solution Overview
Problem
Additive manufacturing processes using laser melting are costly due to the need for manual removal of temporary supporting structures formed to prevent distortions and dissipate heat, which increases process expenses and material consumption.
Innovation Solution
The method involves creating a predefined gap between components based on particle size distribution in the powder bed to provide support during manufacturing, eliminating the need for separate supporting structures and using a sinter bridge layer for temporary fixation between layers, allowing components to be fixed and separated without additional geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If supporting structures are formed to prevent distortions and dissipate heat during additive manufacturing, then component stability and heat dissipation are improved, but manufacturing cost and material consumption increase due to manual removal requirements
Solution Approach 1:
The powder particles in the gap automatically provide support functionality during manufacturing. The particles self-organize to prevent component distortion and dissipate heat without requiring external intervention or separate supporting structures, thereby eliminating manual removal operations and reducing manufacturing costs
Solution Approach 2:
The gap filled with powder particles acts as an intermediary between adjacent components. This intermediary medium provides the necessary support and heat dissipation functions that would otherwise require separate supporting structures, while being inherently integrated into the manufacturing process
2Reliability
If supporting structures are formed to prevent distortions and dissipate heat during additive manufacturing, then component stability and heat dissipation are improved, but material consumption increases
Solution Approach 1:
The existing powder particles in the gap self-organize to provide support functionality, eliminating the need for additional supporting structure material. The same powder material that would be present anyway serves the dual purpose of filling the gap and providing structural support during manufacturing
Solution Approach 2:
The powder particles in the gap perform multiple functions simultaneously: they fill the space between components, provide mechanical support to prevent distortion, and facilitate heat dissipation. This multi-functionality eliminates the need for separate supporting structures and reduces overall material consumption
3Ease of manufacture
If gap width is reduced to minimize material consumption, then manufacturing cost is improved, but component stability during manufacturing deteriorates
Solution Approach 1:
The gap width is optimized to a specific parameter range that balances material consumption and component stability. By carefully controlling the gap dimensions and powder particle size distribution, the system achieves adequate support functionality with minimal material usage, resolving the trade-off between cost and reliability
4Manufacturing precision
If manual removal of supporting structures is performed, then component precision is improved by eliminating temporary structures, but productivity deteriorates due to additional processing time
Solution Approach 1:
The need for separate supporting structures is extracted and eliminated by using the gap-filled powder particles instead. Since the powder particles are already present and integrated into the manufacturing process, there is no separate supporting structure to remove, thereby maintaining component precision while eliminating the productivity loss associated with manual removal operations
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 approach reduces manufacturing costs by eliminating the need for manual removal of supporting structures and minimizing material consumption, while ensuring component stability and heat dissipation during the additive manufacturing process.
Implementation Method 1
additive laser melting... the powder is melted at least locally in order to manufacture the plurality of components
Implementation Method 2
there will be no displacement of the particles present in the gap and hence a displacement of the components relative to each other. The function of a separately formed supporting structure thus can be assumed by the particles of the powder
Implementation Method 3
a sinter bridge layer is formed between the components of a first and a second component layer for arresting at least two components of different component layers to each other during the manufacturing process
Data Source
AI summary
Methods of manufacturing a plurality of components during an additive manufacturing process by means of a powder including particles, which is at least locally melted in order to form the plurality of components. The plurality of components can be formed in a component layer extending along a manufacturing plane, in which a first component lies adjacent to a second component of the component layer at least in a spatial direction along the manufacturing plane. In this connection it is proposed to provide a gap having a gap width between the first component and the second component of the component layer, which is predefined using a particle size distribution of the particles in the powder.